Master Thesis: Characterization of the Compressive Behavior of Seal on Bipolar Plate Assemblies for Fuel Cell Stacks

Job Description:

About Aerostack & Project Context

Aerostack, a joint venture between Airbus and ElringKlinger AG, is developing high-performance fuel cell stacks to enable zero-emission commercial flight. A critical challenge in this mission is mastering the complex mechanical interaction between hyperelastic polymer seals and ultra-thin, work-hardened metallic bipolar plates (BPP). We are looking for a master's student to define the exact compression tolerance band that guarantees a perfect seal without crushing the metallic structures.

Project Scope

Your primary objective is to characterize the compression behavior of Seal on Bipolar Plate (SoBPP) assemblies and define a safe operating window that directly contributes to a weight-optimized aerospace fuel cell stack.

Key Responsibilities & Tasks

Experimental Characterization: Conduct mechanical compression tests on representative SoBPP assemblies to measure force-displacement responses and identify the onset of localized plastic deformation.

State-of-the-Art Research: Review current literature on the compression behavior of thin metal-polymer assemblies to support your methodology.

Data Synthesis: Define the allowable compression window by identifying exact failure thresholds for both under-compression (leakage) and over-compression (structural collapse).

Hardware Optimization: Translate your experimental findings into actionable design guidelines to minimize the weight of the fuel cell stack compression system.

Start date: November 2026