Seals perform a critical safety function in PEM electrolyzers but are subjected to high thermal, mechanical, and chemical stresses. In the ELYSeal project, ZBT is collaborating with Fraunhofer IMWS to develop practical methods for systematically evaluating degradation, service life, and operational safety.

Typical sealing materials such as EPDM, FKM, and silicone are tested under conditions specific to electrolysis. In these tests, temperature, pressure, contact with media, and exposure duration are varied, and the resulting material changes are analyzed mechanically, chemically, and microstructurally. The goal is to establish reliable test protocols, benchmarks, and safety parameters that enable application-oriented evaluation and qualification of sealing materials.

The project builds on ZBT’s extensive expertise in the fields of electrolysis, measurement and testing technology, aging studies, as well as modeling and data-driven analysis. The existing test infrastructure and expertise enable the experimental investigation and evaluation of electrolyzers under dynamic operating conditions and are also available to industry partners as part of development services and contract research.

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