Hydrogen stack course: design and maintenance
Online course of 300 hours in hydrogen stacks: design and maintenance. 6 modules covering cell and MEA design, bipolar plates and flow fields, stack assembly, testing and characterisation to IEC 62282-7-1, and maintenance and diagnostics, with an assigned technical tutor.
Hydrogen stack course: design and maintenance — studying from the United States
The United States is rapidly expanding its electric vehicle, battery and hydrogen industries, supported by federal incentives and private investment. Battery manufacturing and recycling facilities are growing in states such as Georgia, Tennessee, Michigan and Nevada. Automakers, energy companies and startups are developing cells, charging infrastructure and hydrogen fuel systems. Engineers in this sector work on electrochemistry, power electronics, thermal management and standards for safe and reliable energy storage.
Fees for the United States: US$830 (US Dollars), with instalments and employer sponsorship available.
Relevant bodies in the United States
Typical roles
Questions from the United States
Which US bodies and regulators govern batteries, electric vehicles and hydrogen?
In the US, the Department of Energy supports research in batteries and hydrogen, the EPA and NHTSA regulate vehicle emissions and safety, and the Pipeline and Hazardous Materials Safety Administration oversees hydrogen transport. Professional bodies include SAE International and the Electrochemical Society. SEIUM's private qualifications are not official degrees and their recognition is for employers to determine.
Do US employers in batteries and hydrogen value private engineering qualifications?
US battery makers, EV manufacturers and hydrogen developers generally look for accredited degrees, lab or plant experience, and safety knowledge. A private online qualification may show specialist study, but it is not a standard hiring requirement. Employers assess it individually, and hands-on technical experience usually carries more weight.
Is this study practical from the US alongside a job, and how are fees handled?
Yes, the programmes are fully online and taught in English, so no student visa is needed. Expect about 1,900 hours for a master's, 800 hours for a postgraduate diploma, or 300 hours for a specialist course. Each student has an assigned technical tutor. Fees are payable in instalments, and some employers sponsor training, which you should discuss with your employer.
Take the controls.
Run a real engineering trade-off from this field. Move the sliders, watch the model react in real time and beat the challenge.
What you will be able to do
Design the unit cell and select the MEA materials.
Size bipolar plates and flow fields using CFD simulation.
Define the assembly, compression and integration of the stack.
Apply electrochemical characterisation protocols according to IEC 62282-7-1.
Diagnose flooding, drying and degradation failures in service.
Plan preventive and predictive stack maintenance.
Develop the conceptual design of a complete PEM stack.
Who it's for
- Stack design engineers.
- Electrochemical materials engineers.
- Fuel cell test technicians.
- Hydrogen systems maintenance technicians.
- MEA manufacturing engineers.
- Hydrogen R&D engineers.
- Engineering or science graduates looking to join fuel cell manufacturers.
What you'll work with
- IEC 62282-2-100 (fuel cell modules: safety)
- IEC 62282-7-1 (test methods: single cell performance for PEM fuel cells)
- SAE J2617 (performance testing of PEM fuel cell stack sub-systems for automotive use)
- ISO 14687 (hydrogen fuel quality)
- ISO 23273 (fuel cell road vehicles: safety specifications)
- IEC 62282-3-100 (stationary fuel cell power systems: safety)
- IEC 60079-10-1 (classification of areas: explosive gas atmospheres)
- ISO/TR 15916 (basic considerations for the safety of hydrogen systems)
- COMSOL Multiphysics
- Ansys Fluent
- SolidWorks
- Gamry Echem Analyst
- MATLAB
6 modules
1.1Architecture of the unit cell1.2Selecting the ionomer and membrane thickness1.3Ionomer/carbon ratio in the electrodes1.4MEA manufacturing by CCM and GDE1.5Diffusion papers and cloths with PTFE treatment1.6Gaskets and sealing systems1.7MEA compression tolerances1.8High-temperature PEM fuel cells1.9Specific features of solid oxide fuel cells1.10Workshop: specifying an MEA for 1 A/cm²
2.1Graphite, composite and metallic plates2.2Anti-corrosion coatings and contact resistance2.3Serpentine, parallel and interdigitated flow fields2.4Reactant distribution and pressure drop2.5Integrated cooling channels2.6Stamping and hydroforming of metallic plates2.7Laser welding and plate sealing2.8CFD simulation of the flow field2.9Cost targets and volume production2.10Practical exercise: CFD simulation of a serpentine channel
3.1End plates and current collectors3.2Compression systems with tie rods and bands3.3Contact pressure distribution3.4Manifolds and cell-to-cell uniformity3.5Electrical insulation and leakage currents3.6Cell voltage monitoring3.7Module integration with the balance of plant3.8Automated assembly and quality control3.9Leak-tightness and crossover tests3.10Case study: designing the compression system
4.1Conditioning and break-in protocols4.2Polarisation curves according to IEC 62282-7-14.3Cyclic voltammetry and electrochemically active surface area4.4Crossover measurement by linear sweep voltammetry4.5Stack impedance spectroscopy4.6Accelerated durability tests4.7Stack test benches and their subsystems4.8Post-mortem analysis with SEM and tomography4.9Correlating degradation with operating conditions4.10Laboratory: cyclic voltammetry on a unit cell
5.1Online diagnosis through cell voltage5.2Detecting membrane flooding and drying5.3Performance recovery procedures5.4Cell replacement and refurbishment5.5Preventive maintenance plan for the module5.6Safety during work on hydrogen systems5.7Platinum recycling and waste management5.8Estimating remaining stack life5.9Predictive maintenance with fleet data5.10Case study: diagnosing voltage drop in cells
6.1Power, voltage and service-life requirements6.2Cell design and material selection6.3Flow field and cooling design6.4Designing the compression system and manifolds6.5Characterisation test plan6.6In-service diagnostic strategy6.7Maintenance and end-of-life plan6.8Stack cost estimate6.9Report and presentation6.10Final project: final review with the tutor
How you'll learn
100% online training on the SEIUM campus, with downloadable material, recorded classes and an assigned technical tutor. There are no fixed timetables: you progress at your own pace within the intake, so you can combine it with your job.
Each module combines theory, guided reading of the original standard and applied exercises. The working software is COMSOL Multiphysics, Ansys Fluent, SolidWorks, Gamry Echem Analyst and MATLAB, in free, academic or evaluation versions. Tests are studied through real procedures: electrochemical characterisation of unit cells, accelerated durability testing of stacks and diagnosis of stacks in fleet vehicles. Assessment is continuous by module, plus the final project.
Standards covered: IEC 62282-2-100, IEC 62282-7-1, SAE J2617, ISO 14687, ISO 23273, IEC 62282-3-100, IEC 60079-10-1, ISO/TR 15916.
Build it end to end
Your final project follows the real engineering workflow, step by step, reviewed by your tutor.
Where this takes you
Requirements
- No prior qualification is required.
- An internet connection and a computer capable of running the programme software.
- English sufficient to read technical standards.
Ready to start?
Send your application today. Our admissions team replies within 72 hours with your study plan and funding options.
Frequently asked questions
The programme totals 300 hours over 3 months. You set your own pace within each intake, and your tutor helps you plan the workload around your job.
You work with COMSOL Multiphysics, Ansys Fluent, SolidWorks, Gamry Echem Analyst and MATLAB, using free, academic or evaluation versions. Your tutor indicates the free alternative wherever one exists.
A SEIUM Institute certificate, awarded on passing the continuous assessment and the final project. It is SEIUM's own qualification, not an official state degree; its recognition depends on the programme completed and the regulations of each country.
Yes. Modules passed are recognised in a higher programme in the same area (postgraduate diploma or master's). Ask about the recognition policy when you enrol.
No prior qualification is required; you need an internet connection, a computer that can run the programme software and English sufficient to read technical standards.
Start dates are set by SEIUM's faculty for each intake. Our admissions team will confirm the next available date when you apply.
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