In this thesis, thermodynamic models are developed to evaluate and optimize alternative heat integration concepts for iron-based hydrogen storage. The focus is on efficient recovery and integration of process heat to generate both energy and cost advantages. Finally, promising concepts are sized and economically assessed, leading to concrete recommendations.

This master’s thesis investigates the integration of metallic energy carriers into large-scale energy systems. Metallic energy carriers are first implemented in the open-source framework PyPSA (Python for Power System Analysis). Subsequently, their role and potential in future multimodal energy systems are analyzed.

Robots are extremely versatile machines with almost endless application possibilities. In the course of an exhibition, a prototype demonstrator of these diverse applications was developed, in which our 7-axis collaborative robot arm ‘Rica’ is used to draw faces. Images are converted into line drawings and paths to be traversed are calculated from them. This demonstrator is now to be further developed and upgraded.

Two unique test rigs are operated at the FST for the dynamic characterization of flow through annular gaps, such as those used in fuel pumps in the aerospace industry (e.g. Ariane 5 launch vehicle). As part of the work, one of the two test rigs, the test rig for investigating laminar annular gap flow, is to be expanded, put into operation and used to investigate the dynamic properties of the annular gap flow in the transitional region between laminar and turbulent flow.

The dynamic behaviour of modern turbomachinery, such as those used in fuel pumps in the aerospace industry (e.g. Ariane 5 launcher), is largely determined by the dynamic properties of combined axial and radial annular gaps. These annular gaps are primarily found in axial thrust balancing devices in centrifugal pumps. To date, however, the dynamic influence of these machine elements is largely unknown. For this reason, a worldwide unique test rig was built at the FST, which will be put into operation in this thesis.

The dynamic behaviour of modern turbomachinery, such as those used in fuel pumps in the aerospace industry (e.g. Ariane 5 launch vehicle), is largely determined by the dynamic properties of combined axial and radial annular gaps. The identification of these properties is often associated with great experimental and numerical effort. However, a time-effective calculation is indispensable for the prediction of modern turbomachinery. For this reason, an existing tool for the efficient calculation of radial flow annular gaps is to be extended to the calculation of the dynamic characteristics of these annular gaps.

The dynamic behaviour of modern turbomachinery, such as fuel pumps used in the aerospace industry (e.g. Ariane 5 launch vehicle), is largely determined by the dynamic properties of the annular gap. For operational or design reasons, the flow in the annular gap can be either single-phase or two-phase. However, depending on the gas content, this has a significant effect on the dynamic properties of the annular gap. For this reason, an existing tool for the efficient calculation of axial annular gaps with two-phase flow will be extended to include the calculation of the dynamic properties.

Subject areas:

1. Simulate Contact Deformation in FEM (Siemens NX)

2. Parametric Simulation Studies

3. Stress Distribution and Stiffness Analysis

4. Computational Tolerance Analysis

Electric machines generate heat due to electrical losses and mechanical friction, with cooling in the rotor-stator gap typically limited to air circulation. This study explores the effect of introducing small liquid droplets into the airflow to enhance heat transfer. By investigating aerosol-based cooling, this research aims to enhance thermal management and improve the efficiency of electric machines. The project involves designing a small gap (outer cylinder), and connecting it to an existing setup, then conducting experiments to generate and analyze aerosol flow in the gap. The impacts of droplets will be recorded and analyzed, then the aerosol generator with 3 different nozzles will be characterized.

Robots are extremely versatile machines with almost endless application possibilities. In the course of an exhibition, a prototype demonstrator of these diverse applications was developed, in which our 7-axis collaborative robot arm ‘Rica’ is used to draw faces. Images are converted into line drawings and paths to be traversed are calculated from them. This demonstrator is now to be further developed and upgraded.

The Institute of Mechatronic Systems in Mechanical Engineering is conducting research into energy-efficient drive concepts for electric robot vehicles. To better assess the potential for future drive and transport concepts, these must be tested using simulations. In order to be able to assess the influence of a traffic environment, a traffic simulation of the city centre of Darmstadt is therefore used at the IMS. This is implemented in the SUMO simulation software. An initial approach to parameterizing the simulation was developed in previous works and is now to be continued.

In the Clean Circles project, the potential and implementation of iron as a sustainable energy carrier are being investigated. Fluidized beds have proven to be a promising reactor concept in this context. The aim of the work is to develop one-dimensional models that enable predictive forecasts, support upscaling, and can be integrated into comprehensive process models.

The Institute for Simulation of Reactive Thermo-Fluid Systems (STFS) conducts cutting-edge research on reactive flows and alternative energy carriers. One of our focus areas is the combustion of metallic fuels, which have the potential to play a key role in future energy systems.

Aluminum, in particular, undergoes a unique combustion process where evaporated metal reacts with steam, forming hydrogen and aluminum oxide. The global reaction and transport rates are controlled by a multitude of tightly coupled processes, including phase changes, gas phase reactions, thermophoresis, and droplet shape evolution—key aspects that are not yet fully understood.

In this thesis, you will contribute to refining numerical models for these processes using OpenFOAM-based simulations. Your work will help improve the predictive capabilities of existing models, enabling more accurate simulations of aluminum combustion.

Do you have experience in CFD, physical modeling, or programming (Python/C++) in a Unix-based environment? If not, are you eager to develop these skills? If so, we encourage you to contact us for more information!

Subject areas:

1. Finite Element Method (FEM), via Siemens NX

2. Parametric Simulation Studies

3. Stress Distribution and Stiffness Analysis

4. Computational Tolerance Analysis

Metals such as iron and aluminum offer a promising solution for CO₂-neutral high-temperature heat and hydrogen production. Their high energy density, transportability, and regenerability make them an innovative alternative for the energy transition. Your task: Analyze market and competitive structures, identify opportunities, and develop viable business models to unlock the full potential of metal-based energy carriers. Contribute actively to shaping a sustainable energy future!

The increasing share of renewable energies in electricity generation as a result of the energy transition is also leading to a growing demand for energy storage systems that can bridge the time lag between generation and consumption. Electrolysers, which convert electricity into hydrogen, and Carnot batteries (CB), which store electrical energy by converting it into thermal energy, are two possible forms of storage. By combining the two technologies, the waste heat from the electrolyser can be used to increase the efficiency of the CB.

Due to the increasing frequency of extreme weather conditions, aircraft icing events are becoming more prevalent. The study of this phenomenon has gained significant attention, particularly in the field of aviation safety. Our research aims to enhance this understanding by investigating the effects of moving surfaces with drop impact, simulating conditions similar to those experienced by a helicopter. The project involves conducting experiments using an existing setup that creates a single water drop impact onto a rotating disk (very small changes could be required). The impact is recorded using a synchronized infrared and high-speed camera. The recorded images will be analyzed, and the thickness of the resulting ice layer on the disk will be measured using a chromatic line sensor (CLS).

Revoltech is a young start-up at TU Darmstadt that develops sustainable leather alternatives. In order to substantiate the sustainability of one of their products, MATTR, with facts and figures, a Life Cycle Assessment (LCA) is now to be carried out. The scientific challenge here is dealing with missing data on a product in the development stage and formulating sustainability requirements.

The evaporation of liquid droplets, a phenomenon ubiquitous in daily life, has garnered significant attention in scientific research. Of particular interest is the evaporation of droplets laden with nonvolatile solutes, which results in intricate deposition patterns on the substrate. Understanding the mechanisms underlying the formation of these patterns is crucial for various technical applications, spanning from coating and inkjet printing to disease detection. This work delves into the development of a comprehensive model of the specific ring-like deposition patterns observed during the drying of droplets.

As part of the FlowForLife research project, a microfluidic supply network for 3D cell clusters is being developed. One aspect of the network design is the oxygen transport in the surrounding matrix. To characterize this, oxygen quenching luminescent particles are added to the surrounding matrix. The oxygen concentration can be determined at each particle.

From these sparse pointwise concentration data, the flow field in the porous surrounding matrix is to be determined. A solution of the convection-diffusion equation representing the measured concentration field must be found so that conservation of mass and momentum is satisfied in the underlying flow field. Physically-informed neural networks (PINNs) are a promising approach to find such a solution. In this thesis a PINN code should be developed and the achievable accuracy is to be evaluated. The following tasks could be part of the thesis: