Ceramic pressure sensor platform for hydrogen management

With the energy transition, the demand for sensor applications for hydrogen management in production, transport, storage and use is growing significantly. According to the current state of the art, gold-coated metallic or silicon pressure membranes are used. Due to hydrogen corrosion and diffusion, their service life and reliability are limited. In contrast, ceramics are hydrogen-tight, inert and temperature-resistant. Nevertheless, ceramic materials have hardly been used in hydrogen technology to date. Fraunhofer IKTS has therefore teamed up with partners to develop new hydrogen pressure sensors for low pressures up to 2.5 bar – specifically for applications in electrochemical hydrogen production and processing in fuel cells. Two sensor concepts were created and compared for suitability.

1.    The sensor consists of a ceramic membrane and a ceramic base body, which are manufactured separately and then joined in a gas-tight manner using laser beam soldering with special glass solders. The exclusive use of hydrogen-tight ceramics and glass solders ensures high safety and a long service life.

2.    The sensor consists of a ceramic membrane and a base body made of a special ceramic-like composite (polymer ceramic) developed at Fraunhofer IKTS. It is manufactured using an injection molding process with an integrated membrane, which simplifies the process and significantly reduces costs.

The new flush-mounted sensor design prevents condensation or freezing of water vapour in the hydrogen under real conditions, thereby avoiding signal interference and damage to the sensor. The sensor is integrated via a press connection with a 60° cone and does not require any additional sealing materials.

• Project: Development of a ceramic pressure sensor platform for hydrogen management in the field of sustainable and intelligent mobility, energy supply and industrial materials management of the future
• Funding: Federal Ministry for Economic Affairs and Energy, accompanied by the project management agency Jülich / Forschungszentrum Jülich GmbH
• Funding code (FKZ): 03EN5025A-F
• Partners: Siegert Thinfilm Technology GmbH, Rauschert Heinersdorf-Pressig GmbH, FKT Formenbau und KunststoƯtechnik GmbH, Günter-Köhler-Institut für Fügetechnik und Werkstoffprüfung, IL Metronic Sensortechnik GmbH