Wire-Arc Directed Energy Deposition Solutions for LH2, GH2 and Physiosorbed Absorbed Lightweight Aluminium-Based Hydrogen Storage Systems with Integrated Thermal Management for Carbon-Free Mobility Applications

Beschreibung

In the course of the global transition to carbon-free mobility, hydrogen will play a decisive role in the decarbonization of transport. However, the development of efficient, lightweight and safe storage solutions for hydrogen remains a major challenge. Currently, there are three primary types of hydrogen storage - liquid (LH2), gaseous compressed (GH2), and physisorbed - all of which pose unique hurdles in terms of scalability, cost and safety. To overcome these challenges, innovative manufacturing technologies are being explored to produce lightweight storage tanks that meet the stringent requirements for hydrogen storage. One promising approach is wire Directed Energy Deposition (wDED), which offers high deposition rates, low geometrical constraints, a good cost-to-weight ratio and the possibility of integrating functional components into storage systems. In our studies, the manufacturability of three lightweight A5183 Al hydrogen storage vessels for LH2, GA2, and physisorbed hydrogen storage using wDED was demonstrated and is presented. The chosen alloy exhibits natural hardening properties so that no heat treatment processes are required for large components. Each storage system has a unique thermal management solution with heat exchangers produced by laser powder bed fusion (L-PBF) or wDED itself. In detail, the realization of a completely additively manufactured cryogenic GH2 system for mobility applications combining L-PBF, wDED and polymer-based DED is shown, including microstructural and mechanical properties as well as component testing. The suitability of additive manufacturing, in particular wDED, for the manufacturing of lightweight hydrogen storage systems could be successfully demonstrated and enables new solutions for carbon-free mobility.

Zeitraum	6 Okt. 2025
Ereignistitel	ASTM International Conference on Advanced Manufacturing
Veranstaltungstyp	Workshop
Ort	Las Vegas, USA/Vereinigte Staaten, NevadaAuf Karte anzeigen
Bekanntheitsgrad	International