Design and manufacturing process for a metal-supported, proton-conducting solid oxide fuel cell for the direct use of ammonia as a fuel in aviation

Status: ongoing

Project acronym: NH3Avi
Duration: October 1, 2025 – January 31, 2029
Funding ID / Project Sponsor: 20M2439A, DLR
Program Context: LuFo Klima VII-1 KTF – “Climate-Neutral Flying” (https://luftfahrtforschungsprogramm.de/)

Climate-neutral flying requires new energy sources and innovative technologies. In the NH3Avi project, we at the INP are collaborating with the Fraunhofer Institute for Laser Technology (ILT), the Chair of Materials in Electrical Engineering 2 at RWTH Aachen University, and the Center for Fuel Cells (ZBT) to develop a scalable manufacturing process for a direct ammonia solid oxide fuel cell (DA-SOFC). The concept aims to enable the use of ammonia as a carbon-free energy source in aviation, thereby contributing to emission-free flight. 

At the INP, a metal substrate with optimized porosity is being developed as part of the collaborative SOFC project. Atmospheric plasma spraying (APS) is being used for this purpose. The substrate is designed to be porous enough to allow ammonia to be transported efficiently to the anode and to support the interaction between the individual electrode and membrane layers. At the same time, the substrate is optimized to remain stable even under dynamic operating conditions and ambient temperatures, preventing damage such as layer delamination or changes in the crystal structure. To investigate this, a wide variety of analyses are performed using scanning electron microscopy (SEM), high-resolution transmission electron microscopy (HRTEM), X-ray diffraction (XRD), impedance spectroscopy, and electrochemical half-cell tests.

Project partner:
Fraunhofer Institute for Laser Technology ILT
Chair of Materials for Electrical Engineering 2 (IWE2) at RWTH Aachen University
Leibniz Institute for Plasma Research and Technology (INP)
ZBT – Center for Fuel Cell Technology