Hydrogen fuel cell welding

We’re dedicated to the advancement of clean energy, specifically lowering emissions. Hydrogen fuel cell welding on three-pass heat exchange components for electric vehicles is one of our top concentrations. Hydrogen fuel cell weld testing is not a standalone service but part of each project. We can also assist with the development of your hydrogen production systems and hydrogen dispensing systems.

The growing demand for clean energy, including hydrogen fuel cell-powered vehicles and hydrogen fuel cell-refueling stations is a major reason the global fuel cell market will reach $20.2 billion by 2026, with an anticipated increase of 17.9% in sales per year. The demand for competent hydrogen fuel cell welding will increase, too. 

TIG welding for clean energy industry

TIG welding, also known as gas tungsten arc welding, is the preferred method for welding hydrogen fuel cell components. This method is known for its exceptional precision and cleanliness, both critical requirements for the clean energy industry. TIG welding uses a non-consumable tungsten electrode to create a precise arc, joining metals with high heat while being shielded from oxidation by high-purity argon gas.

In TIG welding, two metals join together by heat from an arc created by a non-consumable tungsten electrode and a base metal. To protect against oxidation, Axenics uses an inert shielding gas of high-purity argon.

TIG welding offers a superior solution for welding critical joints, and for situations where small or exceptionally precise welds are required. TIG welding results in the best quality welds for hydrogen fuel cell components.

The three-pass heat exchanger fuel cells we can weld vary in diameters ranging from 1/16th-inch to ½-inch to 3-inch. The shell of the fuel cell is seamless stainless steel 310 schedule 40. However, within the welds, there can be a variety of stainless steel, ranging from 308, 316 and 310. The steel options have different diameters and varying thicknesses, ranging from .45-inch and .65-inch wall thickness to ⅞-inch diameter to 1.25-inch. The final shell is schedule 540 with 5/16-inch thickness.

The variations in stainless steel require a highly-skilled welder to alter the steel’s performance several times throughout the welding process, changing with the thickness of the steel wall. This hydrogen fuel cell welding process process also involves exceptionally high pressure and matching high heat. Welders inspect the steel for possible gouges or other defects in material through the process. They use a borescope or internal camera to check progress. The quality control department performs a similar check after the welding.

Key Benefits of TIG Welding:

• Ultra-clean results: Ideal for applications where contamination must be avoided.
• Exceptional precision: Perfect for small, intricate welds or critical joints.
• Material versatility: Handles a variety of metals, including stainless steel alloys commonly used in fuel cells.

Cleanroom welding

Hydrogen fuel cell welding must remain ultra-clean, Axenics does this work in a Class 100 cleanroom. The room is vacuumed, dusted and inspected internally twice per week. An air purification/filtration system is used and the team inside wears special attire to avoid any skin that may flake from their bodies from getting into the environment. Tools are cleaned before going into the cleanroom. Regular air-quality testing occurs, ensuring miniscule dirt and dust particles aren’t in the space.

Hydrogen Welding Advances Clean Energy with Precision and Expertise

We are committed to supporting the advancement of clean energy by delivering exceptional welding solutions tailored to the growing demands of the hydrogen fuel cell industry. As hydrogen fuel cell technology becomes increasingly integral to the future of clean energy, including in electric vehicles and hydrogen refueling stations, the need for precision welding and rigorous testing grows exponentially.

Hydrogen Welding and the Clean Energy Revolution

Hydrogen fuel cells are at the forefront of the clean energy movement, with applications spanning from powering electric vehicles to creating efficient hydrogen production and dispensing systems. The global fuel cell market is projected to reach $20.2 billion by 2026, with an annual sales growth rate of 17.9%. To support this growth, high-quality hydrogen welding is essential for creating reliable, durable components that meet the strict performance and safety standards of this innovative industry.

Complex Hydrogen Fuel Cell Components

Our expertise extends to three-pass heat exchanger fuel cells, which require welding components with varying diameters, thicknesses, and stainless steel alloys. These components range from 1/16-inch to 3 inches in diameter, with wall thicknesses from 0.45 inches to 5/16 inches. Welders must adapt to these variations during the process, adjusting for changes in heat and pressure to maintain structural integrity.

Each hydrogen fuel cell weld involves:

• Inspecting materials: Detecting gouges, defects, or imperfections using tools like borescopes.
• Managing high pressure and heat: Ensuring consistent performance across materials with varying properties.
• Quality control checks: Verifying every weld to guarantee performance and reliability.

Cleanroom Welding for Hydrogen Fuel Cells

Hydrogen fuel cell welding requires an ultra-clean environment, and Axenics performs these operations in a Class 100 cleanroom. This controlled space ensures that no contamination compromises the integrity of the welds.

Our cleanroom is maintained to the highest standards, including:

• Frequent cleaning: Vacuuming, dusting, and internal inspections twice weekly.
• Air filtration systems: Regular air-quality testing to eliminate dirt and dust particles.
• Specialized attire: Team members wear gear to prevent skin or debris contamination.
• Clean tools: All tools are thoroughly cleaned before entering the cleanroom.

Hydrogen fuel cell welding testing

Axenics performs both non-destructive and destructive tests on every welding project, including weldments for three-pass heat exchanger hydrogen fuel cells. Some customers require a randomly-selected destructive test on the welds as well. Cutting, bending or flattening the weld occurs in order to ensure it comes apart in the correct manner. If a weld does not break down in its intended way, that means it wasn’t welded properly.

Types of testing methods include:

• Visual inspections (often combined with other testing methods)

• Helium leak testing for welds on three-pass heat exchanger fuel cells involves administering a vacuum on the various weldments. Then helium is sprayed in tiny amounts on potential leak areas. A Mass Spectrometer Leak Detector (MSLD) “pulls” helium into the welds. The MSLD sounds an alarm if there is a leak. Pressure helium tests use pressurized helium and a sniffer probe connected to the MSLD around potential leak areas. The sniffer probe pulls the helium through the leak and into the MSLD to sound the alarm.
• Dye penetration testing utilizes water pressure to identify leaks. In the case of hydrogen fuel cells, the component is filled with water or another liquid that has a dye added. Once the liquid hits a pressure higher than the working pressure for the cell, it holds there for a predetermined amount of time. Potential leaks are visible thanks to the dye.
• Ultrasonic weld testing is not common for us, but it’s a highly reliable procedure. Ultrasonic testing locates the exact position of a weld discontinuity more accurately than even radiographic testing (which uses x-rays to detect weld flaws).

Our team has 40+ years experience in clean energy technology for the alternative energy industry. Reach out today with any questions. 

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