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NASA NTRS2003

Proton Exchange Membrane (PEM) Fuel Cell Status and Remaining Challenges for Manned Space-Flight Applications

The Fuel Cell has been used for manned space flight since the Gemini program. Its power output and water production capability over long durations for the mass and volume are critical for manned space-flight requirements. The alkaline fuel cell used on the Shuttle, while very reliable and capable for it s application, has operational sensitivities, limited life, and an expensive recycle cost. The PEM fuel cell offers many potential improvements in those areas. NASA Glenn Research Center is currently leading a PEM fuel cell development and test program intended to move the technology closer to the point required for manned space-flight consideration. This paper will address the advantages of PEM fuel cell technology and its potential for future space flight as compared to existing alkaline fuel cells. It will also cover the technical hurdles that must be overcome. In addition, a description of the NASA PEM fuel cell development program will be presented, and the current status of this effort discussed. The effort is a combination of stack and ancillary component hardware development, culminating in breadboard and engineering model unit assembly and test. Finally, a detailed roadmap for proceeding fiom engineering model hardware to qualification and flight hardware will be proposed. Innovative test engineering and potential payload manifesting may be required to actually validate/certify a PEM fuel cell for manned space flight.

Reaves, Will F.↗

DOE OSTI2020

Validation of an Advanced High-Pressure PEM Electrolyzer and Composite Hydrogen Storage

One of the challenges associated with transitioning our nation’s transportation economy to any alternative fuel is bringing fuel production, storage, transportation, and end-customer delivery infrastructure online. There are challenges associated with planning and implementing hydrogen fueling stations at locations relevant to the parallel effort of bringing the related transportation vehicles into the market. There are additional challenges associated with the operation of hydrogen fueling stations and reducing operating costs through energy reduction. Through calculation and design efforts it was concluded that elevating the pressure of a PEM cell stack and further developing hydrogen processing equipment that support elevated pressures while maintaining similar characteristics to their current production counterparts will yield in energy savings and by extension cost reductions. In this report, the design of a 57-bar (827-psig) electrolysis system and electrolysis cell stack is described. Furthermore, the fabrication, component verification, and integrated testing are summarized. Prior to this development effort, Proton had demonstrated thousand of hours of durability on 30-bar (435-psig) differential pressure PEM electrolysis hardware. Proton has sold and installed many of these 30-bar devices at customer sites. Through this project, Proton has developed and tested 57-bar PEM electrolysis, thereby extending the proven capability of PEM electrolysis as a hydrogen generation and electrochemical compression device. A design and validation effort to arrange hydrogen processioning equipment for refueling OEM vehicles was also undertaken within this project. By arranging equipment within two 6-meter ISO shipping containers and further developing NFPA 2 Hydrogen Technologies Code to support containerized hydrogen equipment, efforts to site, install, and commission, and approve hydrogen fueling stations were reduced and now provide a groundwork for future installations.

08 HYDROGEN↗

NASA NTRS2000

Compendium of NASA Data Base for the Global Tropospheric Experiment's Pacific Exploratory Mission-Tropics B (PEM-Tropics B): DC-8 - Volume 1

This report provides a compendium of NASA aircraft data that are available from NASA's Global Tropospheric Experiment's (GTE) Pacific Exploratory Mission-Tropics B (PEM-Tropics B) conducted in March and April 1999. PEM-Tropics B was conducted during the southern-tropical wet season when the influence from biomass burning observed in PEM-Tropics A was minimal. Major deployment sites were Hawaii, Kiritimati (Christmas Island), Tahiti, Fiji, and Easter Island. The broad goals of PEM-Tropics B were to improved understanding of the oxidizing power of the atmosphere and the processes controlling sulfur aerosol formation and to establish baseline values for chemical species that are directly coupled to the oxidizing power and aerosol loading of the troposphere. The purpose of this document is to provide a representation of aircraft data that will be available in archived format via NASA Langley's Distributed Active Archive Center (DAAC) or are available through the GTE Project Office archive. The data format is not intended to support original research/analysis, but to assist the reader in identifying data that are of interest.

Scott, A. Donald, Jr.↗

NASA NTRS2000

Compendium of NASA Data Base for the Global Tropospheric Experiment's Pacific Exploratory Mission - Tropics B (PEM-Tropics B): P-3B - Volume 2

Scott, A. Donald, Jr.↗

NASA NTRS2001

HO(x) Measurements in PEM Tropics B with the Airborne Tropospheric Hydrogen Oxides Sensor (ATHOS)

The primary objective of PEM Tropics B was to study the processes responsible for the production and loss of tropospheric ozone over the tropical Pacific. This region of the globe contains very clean air as well as aged, polluted air that was advected from both the Asian and American continents. Understanding ozone requires understanding of HO(x) (HO(x) = OH + HO2) chemistry, since the reaction between H02 and NO leads to ozone production and the production of OH often requires ozone loss. In addition, OH is the atmosphere's primary oxidant. Since most atmospheric oxidation is thought to occur in the tropical lower troposphere, measurements during PEM Tropics B should provide an important test of the OH abundances and distributions. Thus, understanding and thoroughly testing HO(x) processes was an important objective of PEM Tropics B. Several issues need to be tested, One is HO, production rates and sources, since HO,, production directly affects ozone production and loss. Another is HO(x) behavior in and around clouds, since HO(x) is lost to cloud particles, but convection may bring HO(x) precursors from near the surface to the upper troposphere. A third is the rise and fall of HO(x) at sunrise and sunset, since these variations give strong indications of the important sources and sinks of HO(x). Making and interpreting high-quality OH and H02 measurements from the NASA DC-8 during PEM Tropics B is the objective of this research effort.

Brune, William H.↗

NASA NTRS2003

Durability of Membrane Electrode Assemblies (MEAs) in PEM Fuel Cells Operated on Pure Hydrogen and Oxygen

Proton exchange membrane (PEM) fuel cells are energy sources that have the potential to replace alkaline fuel cells for space programs. Broad power ranges, high peak-to-nominal power capabilities, low maintenance costs, and the promise of increased life are the major advantages of PEM technology in comparison to alkaline technology. The probability of PEM fuel cells replacing alkaline fuel cells for space applications will increase if the promise of increased life is verified by achieving a minimum of 10,000 hours of operating life. Durability plays an important role in the process of evaluation and selection of MEAs for Teledyne s Phase I contract with the NASA Glenn Research Center entitled Proton Exchange Membrane Fuel cell (PEMFC) Power Plant Technology Development for 2nd Generation Reusable Launch Vehicles (RLVs). For this contract, MEAs that are typically used for H2/air operation were selected as potential candidates for H2/O2 PEM fuel cells because their catalysts have properties suitable for O2 operation. They were purchased from several well-established MEA manufacturers who are world leaders in the manufacturing of diverse products and have committed extensive resources in an attempt to develop and fully commercialize MEA technology. A total of twelve MEAs used in H2/air operation were initially identified from these manufacturers. Based on the manufacturers specifications, nine of these were selected for evaluation. Since 10,000 hours is almost equivalent to 14 months, it was not possible to perform continuous testing with each MEA selected during Phase I of the contract. Because of the lack of time, a screening test on each MEA was performed for 400 hours under accelerated test conditions. The major criterion for an MEA pass or fail of the screening test was the gas crossover rate. If the gas crossover rate was higher than the membrane intrinsic permeability after 400 hours of testing, it was considered that the MEA had failed the test. Three types of MEAs out of the nine total membranes failed the test. The evaluation results showed that fuel cell operating conditions (current, pressure, stoichiometric flow rates) were the parameters that influenced the durability of MEAs. In addition, the durability test results indicated that the type of membrane was also an important parameter for MEA durability. At accelerated test conditions, the MEAs with casted membranes failed during the 400 hour test. However, the MEAs prepared from the casted membrane with support as well as extruded membranes, both passed the 400h durability test at accelerated operating test conditions. As a result of the MEA accelerated durability tests, four MEAs were selected for further endurance testing. These tests are being carried out with four-cell stacks under nominal fuel cell operating conditions.

Stanic, Vesna↗

NASA NTRS2004

Application of Thermo-Mechanical Measurements of Plastic Packages for Reliability Evaluation of PEMS

Thermo-mechanical analysis (TMA) is typically employed for measurements of the glass transition temperature (Tg) and coefficients of thermal expansion (CTE) in molding compounds used in plastic encapsulated microcircuits (PEMs). Application of TMA measurements directly to PEMs allows anomalies to be revealed in deformation of packages with temperature, and thus indicates possible reliability concerns related to thermo-mechanical integrity and stability of the devices. In this work, temperature dependencies of package deformation were measured in several types of PEMs that failed environmental stress testing including temperature cycling, highly accelerated stress testing (HAST) in humid environments, and bum-in (BI) testing. Comparison of thermo-mechanical characteristics of packages and molding compounds in the failed parts allowed for explanation of the observed failures. The results indicate that TMA of plastic packages might be used for quality evaluation of PEMs intended for high-reliability applications.

Sharma, Ashok K.↗

NASA NTRS2011

NASA's Habitat Demonstration Unit (HDU) Pressurized Excursion Module (PEM) In-Field Demonstration at Desert RATS 2010

This paper describes the construction, assembly, subsystem integration, transportation, and field testing operations associated with the Habitat Demonstration Unit (HDU) Pressurized Excursion Module (PEM) and discusses lessons learned. In a one-year period beginning summer 2009, a tightly scheduled design-develop-build process was utilized by a small NASA "tiger team" to produce the functional HDU-PEM prototype in time to participate in the 2010 Desert Research and Technology Studies (Desert RATS) field campaign. The process required the coordination of multiple teams, subcontractors, facility management and safety staff. It also required a well-choreographed material handling and transportation process to deliver the finished product from the NASA-Johnson Space Center facilities to the remote Arizona desert locations of the field test. Significant findings of this paper include the team s greater understanding of the HDU-PEM s many integration issues and the in-field training the team acquired which will enable the implementation of the next-generation of improvements and development of high-fidelity field operations in a harsh environment. The Desert RATS analog environment is being promoted by NASA as an efficient means to design, build, and integrate multiple technologies in a mission architecture context, with the eventual goal of evolving the technologies into robust flight hardware systems. The HDU-PEM in-field demonstration at Desert RATS 2010 provided a validation process for the integration team, which has already begun to retool for the 2011 field tests that require an adapted architecture.

Tri, Terry O.↗

NASA NTRS2019

Thermal System Sizing Comparison of a PEM and Solid Oxide Fuel Cell Systems on Mars

Power production is a key aspect to any Mars mission. One method for providing power throughout the day/night cycle, or to satisfy short-duration high-output power needs, is to utilize a regenerative fuel cell system for providing energy storage and nighttime or supplemental power. This study compares the total system mass for two types of fuel cell systems, proton exchange membrane (PEM) and solid oxide (SO), sized to provide 10 kW of electrical output power in the Mars environment. Two operating locations were examined; one near the equator at 4 Â°S latitude and one the higher northern latitude of 48Â°N. The systems were sized to operate throughout the year at these locations, where the radiator was sized for the worst-case warm condition and the insulation was sized for the worst-case cold condition. Using the selected system parameters, the results for both latitudes showed that the lightest system was the SO fuel cell with a PEM electrolyzer. This was mainly due to the higher operational temperature of the SO system enabled a significantly smaller radiator mass compared to that of the PEM fuel cell system. However, there was a significant difference in mass for the PEM system when operated near the equator as compared to the higher northern latitude. For the 10-kW output system this difference in mass was just under 100 kg.

Fuel Cells↗

DOE OSTI2025

Innovative Method for Reliable Measurement of PEM Water Electrolyzer Component Resistances

Understanding the sheet resistance of porous electrodes is essential for improving the performance of polymer electrolyte membrane (PEM) water electrolyzers and related technologies. Despite its importance, existing methods often fail to provide reliable and comprehensive data, especially for porous materials with complex morphologies and non‐uniform thicknesses. This study introduces a robust and straightforward method for determining the sheet resistance of porous electrodes using a novel probe concept based on industrial printed circuit board (PCB) technology. This probe measures resistance across ten distances, ranging from 250 µm to 2500 µm, enabling local mapping of resistance. The study focuses on the sheet resistance of key components in PEM water electrolyzers, including the gas diffusion layer (GDL), porous transport layer (PTL), and catalyst layers deposited on a membrane. Additionally, an image‐processing‐based method is presented to obtain the thickness distribution of the studied catalyst layers, facilitating a detailed analysis of the electrical in‐plane resistivity with thickness variations. Overall, this methodology has the potential to expedite material integration and bridge the gap between electrode engineering and single‐cell testing, thereby advancing the development of PEM water electrolyzers.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

NASA NTRS2002

Investigation of low glass transition temperature on COTS PEMs reliability

Many factors influence PEM component reliability.One of the factors that can affect PEM performance and reliability is the glass transition temperature (Tg) and the coefficient of thermal expansion (CTE) of the encapsulant or underfill. JPL/NASA is investigating how the Tg and CTE for PEMs affect device reliability under different temperature and aging conditions. Other issues with Tg are also being investigated. Some preliminary data will be presented on glass transition temperature test results conducted at JPL.

Glass transition temperature PEMs↗

DOE OSTI2022

Operating Strategies for Dispatchable PEM Electrolyzers that Enable Low-Cost Hydrogen Production

Hydrogen is a pathway to enabling decarbonization across multiple economic sectors that cannot be directly decarbonized with electricity including heat for industrial operations, medium- and heavy-duty transportation applications, long-duration energy storage, and as a feedstock for chemical synthesis. Producing hydrogen at low costs and carbon footprint is likely essential to economically decarbonize these otherwise "hard to decarbonize" sectors. Low-temperature polymer electrolyte membrane (PEM) electrolysis produces hydrogen from water and electricity and is a rapidly developing pathway towards making hydrogen at the scales required for decarbonization applications. The levelized cost of electrolytic hydrogen is dependent on the capital cost, efficiency, and durability of the electrolyzer system as well as the price of electricity supplied to the electrolyzer and the annual utilization of the electrolyzer (capacity factor). Electricity price and capacity factor depend on the source of energy that the system uses and impact other economic factors. Electricity price and capacity factor and the connections between other aspects of hydrogen production via PEM electrolyzers are the focus of this work. PEM electrolyzers have conventionally been operated at high capacity factors using electricity purchased from utilities with a constant price throughout the year. To achieve lower effective electricity prices, recent work has investigated opportunities for electrolyzers to purchase electricity in wholesale markets, where the cost of electricity varies hourly. This option can lead to lower electricity costs when the electrolyzer is a controllable load that ramps up and down rapidly and turns on and off frequently. This configuration and operating strategy capitalizes on times of low wholesale electricity prices and results in lower hydrogen levelized costs than constant operation due to reduced electricity costs even though the reduced capacity factor increases the cost of recovering the capital investment. Cycling on and off frequently also has implications for electrolyzer durability. An electrolyzer configuration where it is directly connected to renewable generation such as wind or solar, only running when the generator is producing energy, has similar implications on operating strategy, hydrogen levelized cost, capacity factor, and durability. This work provides insight into the relationships between dispatchable electrolyzer operating strategies and the cost of producing hydrogen from these systems, outlining strategies and opportunities to minimize production costs while minimizing operations that are likely to negatively impact system durability and efficiency. We find strategies that minimize electrolyzer cycling and the resulting durability impacts while increasing the hydrogen levelized cost only slightly above the minimum. We also find opportunities for batteries to minimize the number of cycles in systems directly connected to renewable generation. These findings outline key opportunities for future electrolyzer deployments and the synergistic benefits between electrolyzers and increased deployment of renewable energy generation like wind and solar. They also inform research and development that is reducing electrolyzer capital cost while managing durability impacts.

electricity markets↗

DOE OSTI2025

Effect of Carbon Support Heat Treatment on the Performance of Ion-Pair High-Temperature PEM Fuel Cells

Heat treatment can significantly alter the physical and chemical properties of carbon supports, thereby influencing the performance of proton exchange membrane (PEM) fuel cells. This study explores how varying carbon heat treatment temperatures—from 1,000 °C to 2,200 °C—affect the structure and performance of platinum-based catalysts in high-temperature PEM fuel cells. Increasing the heat treatment temperature led to a notable decrease in surface area, along with increases in carbon grain size and hydrophobicity. Although the catalyst supported on carbon treated at 1,000 °C exhibited the highest catalyst activity, the MEA using carbon treated at 1,500 °C delivered the best overall fuel cell performance. This is attributed to an optimized balance between hydrophobicity and accessible surface area, which enhances water management and catalyst utilization. These findings underscore the importance of carbon support engineering in improving the efficiency of ion-pair high-temperature PEM fuel cells.

08 HYDROGEN↗

DOE OSTI2025

Catalyst-Vision (PEM Catalyst Layer Image Analysis Tool) [SWR-25-100]

Catalyst-Vision (PEM Catalyst Layer Image Analysis Tool) provides an advanced Python-based tool, primarily designed for use in a Jupyter/Colab notebook, for the quantitative morphological analysis of pre-segmented shapes. While developed for analyzing PEM catalyst layers from microscopy, its methodology is suitable for characterizing any grayscale object provided on a uniform white background. The tool uses a robust computer vision pipeline based on the Euclidean Distance Transform and skeletonization to accurately measure local thickness and tortuosity, providing a comprehensive characterization of an object's geometry and internal texture. If you find this code useful, please cite our preprint as: Chan, Ai-Lin and Hayden, Steven and Harvey, Steven P. and Smeaton, Michelle and Okrucky, Caleb and Watt, John and Ulična, Soňa and Spurgeon, Steven and Jungjohann, Katherine and Alia, Shaun, Mechanism-informed breakdown: understanding degradation by controlling voltage hold patterns in PEM water electrolyzers. Preprint (2025).

Spurgeon, Steven [National Laboratory of the Rocki↗

DOE OSTI2021

MW-Scale PEM-Based Electrolyzers for RES Applications (CRADA CRD-18-00742 Final Report)

Many nations are rapidly increasing electrical generation capacity from renewable energy sources (RES) such as wind and solar. The wide penetration of RES requires an energy storage solution which has come in the form of hydrogen generated via polymer exchange membrane (PEM) electrolysis. A study of the current state-of-the-art PEM electrolysis indicates that the largest PEM-based stacks range from 150 - 250kW and that a significant scale-up of the technology is required to accommodate multi-Megawatt (MW) energy storage solutions in large-scale RES applications.

08 HYDROGEN↗

DOE OSTI2021

Enhancements supporting IC usage of PEM libraries on next-gen platforms

This milestone reports on the culmination of several years of effort by multiple PEM support software development teams to provide capabilities for use in LLNL-developed integrated codes on next-gen ASC platforms, including GPU support. We will provide a survey of relevant Application Program Interfaces (API) that are required to support LLNL IC code capability on relevant architectures, with a focus on Sierra and El Capitan. We will identify and summarize all dependencies between PEM supported libraries and IC supported physics codes. We will provide an assessment of algorithmic improvements that have been deployed, as well as future developments that are required to complete the GPU porting efforts. This assessment will include a description of programming models adopted by each of the PEM projects, distinct algorithmic challenges for each of the capabilities, and information about sharing GPU memory between the APIs and host codes. We will develop targeted test problems to assess computational performance. Finally, this milestone will result in identification of gaps in our effort to assist the LLNL ASC program in prioritization of effort for porting software to El Capitan.

97 MATHEMATICS AND COMPUTING↗

DOE OSTI2026

Advanced PEM Electrolyzer Membrane for Hydrogen Crossover Mitigation

An unintended reaction in the electrochemical conversion of water to hydrogen in proton exchange membrane (PEM) electrolyzers is the crossover of hydrogen from the anode to the oxygen-containing cathode through the membrane, creating hydrogen losses and safety concerns. Efforts to date have focused on embedding platinum catalysts in perfluorosulfonic (PFSA) membranes to convert H 2 to protons. The objective of this project is to design and develop hydrocarbon (HC) proton exchange membranes (PEMs) that can help overcome the risk of high H 2 crossover in current PEM electrolyzer (ELX) stacks by designing and optimizing the gas recombination catalyst (GRC) within the membrane and membrane electrode assembly (MEA) structure.

08 HYDROGEN↗

NASA NTRS1997

Chemical Characteristics of Continental Outflow from Asia to the Troposphere Over the Western Pacific Ocean during February - March 1994: Results from PEM-West B

We present here the chemical composition of outflow from the Asian continent to the atmosphere over the western Pacific basin during the Pacific Exploratory Mission-West (PEM-West B) in February-March 1994. Comprehensive measurements of important tropospheric trace gases and aerosol particulate matter were performed from the NASA DC-8 airborne laboratory. Backward 5 day isentropic trajectories were used to partition the outflow from two major source regions- continental north (greater than 20 deg N) and continental south (less than 20 deg N). Air parcels that had not passed over continental areas for the previous 5 days were classified as originating from an aged marine source. The trajectories and the chemistry together indicated that there was extensive rapid outflow of air parcels at altitudes below 5 km, while aged marine air was rarely encountered and only at less than 20 deg N latitude. The outflow at low altitudes had enhancements in common industrial solvent vapors such as C2Cl4, CH3CCl3, and C6H6, intermixed with the combustion emission products C2H2, C2H6, CO, and NO. The mixing ratios of all species were up to tenfold greater in outflow from the continental north compared to the continental south source region, with Pb-210 concentrations reaching 38 fCi (10(exp -15) curies) per standard cubic meter. In the upper troposphere we again observed significant enhancements in combustion-derived species in the 8-10 km altitude range, but water-soluble trace gases and aerosol species were depleted. These observations suggest that ground level emissions were lofted to the upper troposphere by wet convective systems which stripped water-soluble components from these air parcels. There were good correlations between C2H2 and CO and C2H6 (r(sup 2) = 0.70 - 0.97) in these air parcels and much weaker ones between C2H2 and H2O2 or CH3OOH (r(sup 2) = 0.50). These correlations were the strongest in the continental north outflow where combustion inputs appeared to be recent (1 - 2 days old). Ozone and PAN showed general correlation in these same air parcels but not with the combustion products. It thus appears that several source inputs were intermixed in these upper tropospheric air masses, with possible contributions from European or Middle Eastern source regions. In aged marine air mixing ratios of 03 (approximately equals 20 parts per billion by volume) and PAN (less than or equal to 10 parts per trillion by volume) were nearly identical at less than 2 km and 10 - 12 km altitudes due to extensive convective uplifting of marine boundary layer air over the equatorial Pacific even in wintertime. Comparison of the Pacific Exploratory Mission-West A and PEM-West B data sets shows significantly larger mixing ratios of SO2 and H2O2 during PEM-West A. Emissions from eruption of Mount Pinatubo are a likely cause for the former, while suppressed photochemical activity in winter was probably responsible for the latter. This comparison also highlighted the twofold enhancement in C2H2, C2H6, and C3H8 in the continental north outflow during /PEM-West B. Although this could be due to reduced OH oxidation rates of these species in wintertime, we argue that increased source emissions are primarily responsible.

Talbot, R. W.↗