Laser-based additive manufacturing to help produce ‘green’ hydrogen

15 Oct 2024

German “AM2H2” project is developing multi-material energy converter to boost production efficiency.

In the AM2H2 project, the LZH is working on a multi-material energy converter for the more efficient production of green hydrogen, shown here is an additively manufactured gas burner with internal cooling channels. (Photo: LZH)

Many energy technologists and analysts consider emission-free sources of power to be the future – especially cheaply-generated hydrogen. But in order to achieve this, the combustion process of hydrogen must be improved.

In a new project, Laser Zentrum Hannover (LZH) is working together with three partners from Lower Saxony, Germany, on what they are calling “innovative additively-manufactured supply components”, based on laser technology.

In order to make the production of green hydrogen more efficient, Hanover University of Applied Sciences and Arts (HsH), Leibniz University Hannover (LUH), the Clausthal Center for Materials Technology (CZM), and LZH are conducting research into new types of multimaterial components.

The so-called “innovation alliance” wants to combine assemblies for low temperatures with those for high temperatures. LZH stated, “This multimaterial design should enable more efficient, more compact and lighter components. Both the mobility sector and decentralised energy supply would benefit from this.”

Additively manufactured integrated energy converter

The four partners are working together to additively manufacture a functional, integrated energy converter. To this end, they are developing a hydrogen reformer that uses multimaterial components to convert methanol or ammonia into hydrogen.

Due to the necessary pressure reduction and high reaction temperatures, high temperature differences occur in one component. It is therefore particularly important that all the materials used, both metallic and ceramic, are well coordinated with each other.

In order to manufacture the components quickly and efficiently, the project partners are developing a process head that can flexibly process both powder and wire base materials. In this way, the partners want to enable a gradual transition between two different materials and thus produce so-called functional-graded materials. The project also includes the characterisation and evaluation of the material systems and components.

In the innovation network known as “Additive Manufacturing of Multimaterial Components for Sustainable Energy Conversion” (AM2H2), the CZM is responsible for material development and testing, and characterisation of the materials and components.

LZH is developing laser processes for additive manufacturing, the HsH is conceptualising and manufacturing a process head, while the Institute for Product Development and Device Engineering at the LUH is responsible for simulations and for the construction and design of the system demonstrator. The project is funded by the European Social Fund Plus / European Regional Development Fund.