In the world of industrial manufacturing, time is often the difference between a flawless product and costly waste. This is particularly true in processes like adhesive bonding, where the adhesive’s pot-life—the period during which it remains workable—can make or break production efficiency. Researchers at RWTH Aachen University, led by V Ginster from the ISF – Welding and Joining Institute, have tackled this challenge head-on, combining experimental characterization with advanced simulation to optimize production systems for adhesively bonded electrolyzer cells.
Electrolyzer cells, crucial components in green hydrogen production, require precise handling and stacking operations between adhesive application and final joining. This delay, while necessary, risks exceeding the adhesive’s pot-life, leading to product rejection and scrap. “The key is to understand and mitigate these risks early in the planning phase,” Ginster explains. “Simulation allows us to account for stochastic effects like random machine breakdowns, which significantly influence product lead times.”
The research team conducted a comprehensive study, characterizing a two-component epoxy adhesive using differential scanning calorimetry, rotational rheometry, and 90° peel tests. They derived an application-specific pot-life and integrated it into a discrete-event simulation model of the planned production system. The simulation study, varying buffer size and mean time to repair, revealed a critical trade-off between throughput and pot-life-induced waste. The most favorable configuration emerged as a buffer capacity of one and short repair times.
One of the most compelling findings was the substantial reduction in scrap when extending pot-life through different processing temperatures. This highlights the benefit of integrating curing kinetics and dynamic simulation in early-stage production system design. “By understanding and controlling these factors, we can significantly improve the efficiency and sustainability of electrolyzer cell production,” Ginster notes.
The implications for the energy sector are substantial. As the demand for green hydrogen grows, so does the need for efficient and cost-effective electrolyzer production. This research paves the way for smarter, more adaptive manufacturing processes, reducing waste and enhancing productivity. “Our work demonstrates the power of combining experimental characterization with advanced simulation,” Ginster says. “It’s a approach that can be applied to various time-critical adhesive processes, not just electrolyzer cell production.”
Published in the Journal of Advanced Joining Processes (translated from German as “Journal for Advanced Connection Technologies”), this study offers valuable insights for manufacturers and engineers seeking to optimize their production systems. By embracing these innovative techniques, the industry can move towards more efficient, sustainable, and profitable operations. As Ginster aptly puts it, “The future of manufacturing lies in our ability to adapt and innovate, and this research is a step in that direction.”