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 Location: Aerostack GmbH, Dettingen an der Erms, Germany Duration: 6 months Profile & Qualification Required skills & background Bachelor's degree in Aerospace Engineering, Mechanical Engineering, Computational Engineering, or a comparable field of study

Software and Tools

Solid knowledge of structural mechanics and materials science Initial experience with computer-aided design (CAD) and finite element (FE) modeling Basic programming skills (e.g., Python) Hands-on laboratory e