The work performed during the SOSLeM project has led to the following main results:
• The project partners have developed new and optimised already existing processes for the production of the fuel cell cassettes by lean manufacturing processes, improving the sealing adhesion on the cassettes, and automation of the laser welding process.
• The production time and costs have been reduced and flexibility has been increased by large furnace arrangement and introduction of a multi-stack production station.
• The new developed cassette design has reduced the cassette welding time from 540 seconds to 50 seconds.
• The stack preparation has been improved by advanced sealant curing and stack conditioning, resulting in faster commissioning (time reduced by about 40%) and 35% reduced gas consumption while maintaining high yields.
• Environmental benefits have been realised by the implementation of improved protective coatings for the steel in the fuel cell stack.
The improvements have summed up to a reduction of stack manufacturing costs by about 60%. Together with other improvements made outside of SOSLeM the capital costs could be decreased to about 3,700 €/kW.
An improved waste water cleaning unit was finally not integrated in the existing production line, as the investment costs led to too long payback periods. It is, however, now under reconsideration for the soon to realise new production plant where due to upscaled production rates higher amounts of waste water are anticipated. It further followed that the developed filter to clean the exhaust gas was too bulky to be implemented in the existing system design, and that the developed routines for performing advanced characterisation of the stacks in the end-of-line testing need further refinements. Considerable progress has nevertheless been realised, and thus the results provide a solid basis for future research.
The research performed in SOSLeM has resulted in two PhD theses and was also disseminated to scientific audiences in two peer-reviewed publications. Further articles are expected to be published.
SOSLeM results were also disseminated in a number of conferences and trade fairs (see www.soslem.eu for details). Moreover, two patents were filed as an outcome of the research carried out.
