Future-ready high-tech welding solutions

SST innovation for the Fraunhofer IWU

Steigerwald Strahltechnik, in close collaboration with the Fraunhofer Institute for Machine Tools and Forming Technology (IWU), is developing a specialized system that revolutionizes the production of bipolar plates. These specific plates are a key component of electrolyzers used to produce hydrogen through electrolysis. Hydrogen is a central element in the energy transition and plays a crucial role in the development of sustainable and environmentally friendly technologies.

Advantages of Electron Beam Welding over Laser Welding

Electron beam welding offers numerous advantages over conventional laser scanner welding, significantly improving both efficiency and the quality of weld joints. While laser beam welding relies on focused light being directed along the joint via a mirror system, researchers at the IWU use negatively charged particles in electron beam welding, which strike the workpieces at nearly two-thirds the speed of light. This approach eliminates the need for sluggish mechanical deflection, enabling the electron beam to be guided virtually without delay and considerably increasing the welding speed.

Another major advantage is the flexibility of electron beam welding. Thanks to EBO Jump technology – a high-speed beam deflection technique – multiple process zones can be addressed simultaneously, which is not possible with conventional welding methods in this form. This multi-pool technique allows, for instance, preheating and post-heating processes to occur nearly in parallel, further enhancing the overall efficiency of the procedure.

Image caption:
Department head Frank Riedel (center) and Frank Schüßler, Managing Director of Steigerwald Strahltechnik, inspect a bipolar plate at an electron beam welding system at the Fraunhofer IWU.
© Image: Fraunhofer IWU, Source: Freie Presse, Chemnitzer Verlag und Druck GmbH & Co. KG

Highest Quality Through Vacuum Conditions

Electron beam welding is performed under vacuum conditions, ensuring a stable and interference-free environment. This is particularly crucial, as even the smallest irregularities in the weld seam can result in leakage. By operating in a vacuum, external influences such as fluctuations in air pressure or humidity are eliminated, guaranteeing the highest possible weld seam quality.

Project manager Patrick Urbanek emphasizes: “By using vacuum technology, we can eliminate external influences and achieve what is currently the highest possible weld seam quality.”

Importance for Hydrogen Technology and Sustainability

The new electron beam system developed by Steigerwald represents an important step toward a sustainable future. Hydrogen is considered a key technology for the energy transition, offering a clean and efficient alternative to fossil fuels. By improving the manufacturing processes of electrolyzers, production costs can be reduced and efficiency increased—promoting the wider adoption of hydrogen technologies.

In 2024, the research team at Fraunhofer IWU in Chemnitz is focusing on the further development of this technology, aiming to reach small-scale production readiness by 2025. The new system is an integral part of the Referenzfabrik.H2 (Hydrogen Reference Factory), which builds on the research and development projects of Fraunhofer IWU and other Fraunhofer institutes. The objective is to lay the foundation for the industrial mass production of electrolyzers and fuel cells in order to ensure a sustainable and environmentally friendly energy supply.

With this innovative solution, Steigerwald Strahltechnik is making a significant contribution to the advancement of cutting-edge, environmentally friendly technologies—and supporting the vision of a sustainable future.

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