Fraunhofer Institute for Microstructure of Materials and Systems IMWS
Water electrolysis is considered a key technology for achieving a climate-neutral energy supply. To ensure that electrolyzers can be operated safely, efficiently, and economically over the long term, the materials used must withstand demanding operating conditions. At the same time, it is essential to detect aging and wear processes at an early stage. This is where the “STARK” project of the Fraunhofer Institute for Microstructure of Materials and Systems IMWS in Halle (Saale) comes in. The project aims to develop innovative testing methods that enable the rapid, non-destructive, and on-site assessment of the condition of critical polymer components in electrolyzers, such as membranes and seals.
The project focuses on novel measurement techniques that make changes within materials visible long before a failure occurs. To achieve this, researchers at Fraunhofer IMWS use mobile spectroscopic methods. The data obtained provide insights into changes occurring within plastic components. By combining these results with conventional mechanical and durability testing, the team develops models capable of reliably assessing material condition and predicting potential damage at an early stage.
“Our goal is to identify aging processes in membranes and seals before they lead to technical problems. In the long term, these measurements should be possible directly at operating plants, helping operators plan maintenance activities more effectively and avoid unplanned downtime,” explains Annik Bernhardt, project manager at Fraunhofer IMWS.
To develop these new methods, the project investigates various materials under conditions similar to those found in real electrolyzers. These include elevated temperatures, pressure loads, and different chemical environments. The materials are subjected to accelerated aging and subsequently analyzed. This makes it possible to determine how their properties change over time and which measurement signals indicate the onset of degradation. Particular attention is given to advanced membrane materials, including PFAS-free alternatives that could help reduce future dependence on critical materials.
The methods developed in the project are expected to significantly simplify the quality control and maintenance of electrolyzers. Instead of removing components or sending samples to specialized laboratories, mobile measurement devices could be used to assess component conditions directly on site. Potential damage could therefore be detected early, before it results in unplanned downtime or costly repairs. This increases system availability while also reducing maintenance effort and operating costs.
In addition, the project strengthens hydrogen research in Saxony-Anhalt and builds important expertise in the field of material diagnostics. The Fraunhofer team is creating a comprehensive knowledge base on the aging behavior of membranes and seals that can also be used in future research and industrial projects. By combining innovative materials, realistic aging tests, and advanced diagnostic methods, electrolyzers can be operated more reliably and economically. At the same time, new opportunities are being created for regional services in quality control and materials assessment.
(October 16, 2026)