Klassen, Thomas

Using fuel cells in energy generation makes it possible to provide clean energy in line with the demand. Fuel cells offer a major advantage over other renewable energy sources whose generation is dependent on external influences. However, fuel cells cannot compete economically with conventional energy generation systems such as diesel generators. Such an economical constraint is partly due to the higher energy requirements of hydrogen storage. Metal hydride storage systems offer the possibility of reducing the energy intensity of storage due to low storage pressures. Heat is also required to operate such storage systems, which can be provided from the fuel cell's waste heat. To extract the heat from the fuel cell, a novel cooling circuit structure for large-scale applications is presented and simulated, considering the requirements of the metal hydride storage system regarding temperature (60 °C) and mass flow (60 kg/min). The architecture of the cooling concept consists of a primary and a secondary circuit, whereby the primary circuit is responsible for cooling the fuel cell and the secondary circuit for extracting the heat. Finally, simulation data are presented, which show the system behaviour in the event of changes in the fuel cell's electrical load and the heat consumer's thermal load. This coupling strategy shows that the cooling system is suitable for extracting the waste heat and keeping all essential parameters constant.

In recent years, cold spraying (CS) has emerged as a promising technology for repair applications, particularly for oxidation-sensitive materials. In order to obtain an optimum repair result that fulfills the highest requirements regarding material properties, simple geometric shape restoration is not sufficient. Any additive manufacturing process results in particular features in microstructure, possible defects and respective – potentially even anisotropic – mechanical properties. To systematically tailor these microstructures and properties to the specific component and geometry requires complex routines. This work proposes the design of a knowledge-based cold spray repair system that facilitates a complete individual repair procedure for aircraft components. This system includes the elements of (i) reverse engineering to analyze, classify and generate digital data of the damaged component, (ii) pre-processing to obtain the ideal conditions for the CS process, (iii) toolpath planning to optimize robotics for the CS process, (iv) on-line monitoring to ensure process quality, (v) post-processing and (vi) performance testing of the material properties to meet the challenging requirements of the aerospace industry. By using an industrial robot and computer-aided planning of the trajectories, components are to be repaired under cold spray and geometrical conditions for ideal material deposition. The goal is to obtain repaired components that fulfill the required property profile equally well as respective new parts.

© 2021, The Author(s). Up to now, the role of particle sizes on the impact behavior of ceramic particles in aerosol deposition not yet fully understood. Hence, with the aim to supply a more general understanding, modeling series of low strain rate compression and high-speed impact were performed by molecular dynamics on single-crystalline particles in sizes of 10-300 nm that are tuned to match mechanical properties of TiO2-anatase. The modeling results reveal that particles with original diameter of 25-75 nm exhibit three different impact behaviors that could be distinguished as (i) rebounding, (ii) bonding and (iii) fragmentation, depending on their initial impact velocity. In contrast, particles larger than 75 nm do not exhibit the bonding behavior. Detailed stress and strain field distributions reveal that combination of “localized inelastic deformation” along the slip systems and “shear localization” cause bonding of the small and large particles to the substrate. The analyses of associated temperature rise by the inelastic deformation revealed that heat diffusion at these small scales depend on size. Whereas small particles could reach a rather homogeneous temperature distribution, the evolved heat in the larger ones keeps rather localized to areas of highest deformation and may support deformation and the formation of dense layers in aerosol deposition.