Student Materials Science, Chemistry, Energy Technology, Environmental Engineering, Physics or similar (f/m/x) - Development of Platinum Free/Lean Electrocatalysts for Fuel Cells

The Institute of Engineering Thermodynamics at the German Aerospace Center (Deutsches Zentrum für Luft- und Raumfahrt -DLR) in Stuttgart, with further research facilities in Cologne, Ulm, Oldenburg and Hamburg, does research in the field of efficient energy storage systems that conserve natural resources, and next generation energy conversion technologies with a staff of 180 scientific and technical employees, engineers and doctoral candidates. The spectrum of activities ranges from theoretical studies to laboratory work for basic research and to the operation of pilot plants. These experimental and theoretical studies are accompanied by systems analysis studies to analyse the associated technological, environmental and economic potential and situate it in a larger overall context of the energy economy by means of scenarios. A tight network with the University of Stuttgart -especially with the Institute of Energy Storage- and with the Helmholtz Institute Ulm at the University of Ulm is existing.

Polymer Electrolyte Membrane Fuel Cells (PEMFCs) are an emerging green energy technology used in automotive applications. PEMFCs are electrochemical energy converters, which generate electricity from hydrogen and air, producing only water vapor as an exhaust gas. However, advances in cost, performance and durability are still needed to gain market acceptance. A way to mitigate these critical issues is to develop high performance critical raw material free/lean electrocatalysts. Flame Spray Pyrolysis (FSP) – a unique, high temperature and scalable nanomaterial production technique - could be a suitable method to achieve highly efficient catalysts for PEMFC technology.

This project aims at the development of Platinum free/lean Electrocatalysts for Fuel Cells (Metal Nitrogen Carbon Catalysts and High Entropy Electrocatalysts) using FSP techniques in single step. Unique synthesis conditions used in FSP as compared to conventional routes enable to explore new horizon of materials characteristics. N(S) doped C and Fe/Co/Ni vapor deposition on doped-C will be produced by single (sequential precipitation of Metals and C) and dual (co-precipitation of Metals and C) flame configuration for optimization of density of active sites. The project will expore the potential of FSP techniques and improve the understanding of active oxygen reduction reaction site formation under extreme conditions using various ex-situ characterization techniques.

The main objectives and results are: 

• Development of doped-C and metal vapor deposits by FSP techniques
• understanding the roles of particle formation under extreme conditions in density of active sites and optimizing FSP/precursor composition accordingly for high performance catalyst production
• validating materials performance and durability in half cell and single PEMFC cell level
• thorough post operation degradation investigation for each cell component
• If necessary, sample preparation and material characterization data analysis for SEM, XRD, XPS, AFM, BET and TGA, depositing catalyst layers using electrospray
• written elaboration and documentation