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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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At least 415 records · Page 23
All sourcesNASA NTRSDOE OSTI
DOE OSTI2020

Market Segmentation Analysis of Medium and Heavy Duty Trucks with a Fuel Cell Emphasis

The medium- and heavy-duty transportation sector is experiencing rapid changes in powertrain technology innovation with recent announcements of battery electric and fuel cell electric trucks being offered. However, the economics of these alternative powertrain vehicles are uncertain and difficult to compare directly. This analysis seeks to bridge the gap of techno-economic analyses for these alternative powertrain vehicles by comparing all of them within the same analytic framework. Specifically, this report evaluates the total cost of ownership (TCO) of six different truck powertrain technologies (diesel, diesel hybrid-electric, plug-in hybrid electric, compressed natural gas, battery electric, and fuel cell electric) for three different truck vocations (Class 8 long haul [750 mile range], Class 8 short haul [300 mile range], and Class 4 parcel delivery), for different Department of Energy technology statuses (2018, 2025, and Ultimate). The TCO framework includes direct costs (purchase price, fuel, operating and maintenance), indirect costs (dwell time costs due to refueling/recharging and payload opportunity costs from forgone revenue due to the truck being weight-limited), but excludes general operation costs (driver wages and benefits, insurance, tire replacements, permits, tolls) that are assumed to be the same across powertrains. The TCO was evaluated for four scenarios that reflect typical business operating conditions. The TCO analysis results highlight that each powertrain technology may have an economic advantage on a TCO basis in certain business operating conditions and depending on fuel price realized. For Class 8 long haul trucks when payload opportunity costs are not incurred, battery electric and fuel cell electric powertrains could be cost competitive with diesel if the 2025 targets are achieved and fuel prices are low. If payload opportunity costs are incurred, battery electric powertrains are not estimated to reach TCO parity with diesel even if Ultimate targets and low electricity prices are realized, indicating a need for significant vehicle lightweighting. In Class 8 short haul commercial applications when payload opportunity costs are not incurred, battery electric, fuel cell electric, and compressed natural gas vehicle powertrains have very competitive TCOs with diesel if the 2025 targets are achieved. In Class 8 short haul commercial applications when payload opportunity costs are incurred, the battery electric vehicle powertrains can achieve TCO parity with diesel only if the Ultimate battery prices are met ($80/kWh). In Class 4 parcel delivery truck operating scenarios where there are no dwell time costs incurred, the plug-in hybrid electric vehicle, battery electric vehicle, and fuel cell electric vehicle could be cost-competitive with diesel and compressed natural gas with current (2018) technology performance and costs. In general, the payload opportunity costs can be a significant driver to TCO for the Class 8 long and short haul commercial vehicle applications while the dwell time costs could be a major TCO cost driver for the Class 4 parcel delivery vehicle if the business scenario realizes those costs.

advanced powertrains↗
NASA NTRS1984

Fuel cell design and assembly

The present invention is directed to a novel bipolar cooling plate, fuel cell design and method of assembly of fuel cells. The bipolar cooling plate used in the fuel cell design and method of assembly has discrete opposite edge and means carried by the plate defining a plurality of channels extending along the surface of the plate toward the opposite edges. At least one edge of the channels terminates short of the edge of the plate defining a recess for receiving a fastener.

Myerhoff, Alfred↗
NASA NTRS2003

Unitized Regenerative Fuel Cell System Model Development

A Unitized Regenerative Fuel Cell (URFC) Energy Storage System is being developed at the NASA Glenn Research Center. This URFC system is unique in that it uses the surface area of the hydrogen and oxygen storage tanks as radiating heat surfaces for overall thermal control of the system. The tank surfaces also play an important role in the temperature control of regenerative gas dryers/humidifiers used to dry the hydrogen and oxygen gases produced by electrolysis during the charging and also used to humidify the hydrogen and oxygen gases used by fuel cell during the discharging of the URFCS. A bi- directional pressure controller is used to control the pressure of the oxygen and hydrogen gas inside the URFC stack during both charging and discharging of the URFC system. A water storage accumulator is used to store water reactant and control water pressure inside the URFC stack.

Burke, Kenneth A.↗
NASA NTRS1983

High performance methanol-oxygen fuel cell with hollow fiber electrode

A methanol/air-oxygen fuel cell including an electrode formed by open-ended ion-exchange hollow fibers having a layer of catalyst deposited on the inner surface thereof and a first current collector in contact with the catalyst layer. A second current collector external of said fibers is provided which is immersed along with the hollow fiber electrode in an aqueous electrolyte body. Upon passage of air or oxygen through the hollow fiber electrode and introduction of methanol into the aqueous electrolyte, a steady current output is obtained. Two embodiments of the fuel cell are disclosed. In the first embodiment the second metal electrode is displaced away from the hollow fiber in the electrolyte body while in the second embodiment a spiral-wrap electrode is provided about the outer surface of the hollow fiber electrode.

Lawson, Daniel D.↗
DOE OSTI2020

Bilayer Anion-Exchange Membrane with Low Borohydride Crossover and Improved Fuel Efficiency for Direct Borohdyride Fuel Cell

The development of membranes with low fuel crossover and high fuel efficiency is a key issue in direct borohydride fuel cells (DBFCs). In previous work, we produced a poly(vinyl alcohol) (PVA)-anion-exchange resin (AER) membrane with a low fuel crossover and a low fuel efficiency by introducing Co ions. In this work, a bilayer membrane was designed to improve the fuel efficiency and cell performance. The bilayer membrane was prepared by casting a PVA-AER wet gel onto the partially desiccated Co-PVA-AER gel. The bilayer membrane showed a borohydride permeability of 1.34 × 10 –6 cm 2 ·s –1 , which was even lower than that of the Co-PVA-AER membrane (1.98 ×10 –6 cm 2 ·s –1 ) and the PVA-AER membrane (2.80 × 10 –6 cm 2 ·s –1 ). The DBFC using the bilayer membrane exhibited a higher fuel efficiency (37.4%) and output power (1.73 Wh) than the DBFCs using the Co-PVA-AER membrane (33.3%, 1.27 Wh) and the PVA-AER membrane (34.3%, 1.2 Wh). Furthermore, the DBFC using the bilayer membrane achieved a peak power density of 327 mW·cm –2 , which was 2.14 times of that of the DBFC using the PVA-AER membrane (153 mW·cm –2 ). Finally, the drastic improvement benefited from the bilayer design, which introduced an interphase to suppress fuel crossover and avoided unnecessary borohydride hydrolysis.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Direct Utilization of Pure and Denatured Ethanol in Metal Supported Solid Oxide Fuel Cells

Metal supported solid oxide fuel cells (MS-SOFC) are integrated with internal reforming catalyst for direct utilization of ethanol to generate electricity. MS-SOFCs are operated up to 500 h at 700°C, with water-ethanol blend fuel using high-purity ethanol and denatured ethanol. Performance and durability with denatured ethanol varies dramatically with the composition of the denaturant. Cells operated with three denatured ethanol fuels containing small amount of methanol, isopropanol, and denatonium benzoate demonstrate similar and relative stable performance after stabilization, suggesting that these fuels are fit for MS-SOFC operation. No or minimum carbon deposits are observed on the high entropy alloy-based reforming catalyst layer. Denatured ethanol containing gasoline and toluene leads to fast degradation. Here, MS-SOFCs are promising for direct utilization of denatured ethanol, offering a path to rapid-start, carbon-neutral operation with widely-available fuels.

30 DIRECT ENERGY CONVERSION↗
DOE OSTI2026

BIL High Speed Fuel Cell Stack Manufacturing

General Motors LLC (GM) was awarded a project to develop and implement technologies for manufacturing 20,000 units of Fuel Cell Stacks per year on two shifts per day basis. GM leveraged prior in-house expertise in designing the Fuel Cells, deploying the manufacturing process steps in the laboratory environment as well as the deployment in the industrial environment on a smaller scale. The project focus was to design, build, and deploy a manufacturing line consisting of an anode and cathode electrode processing, unitized electrode assembly, fuel cell stacking, compression, testing, and final assembly of the fuel cell stack. The project was terminated in the first budget period.

08 HYDROGEN↗
DOE OSTI2026

Cummins PEM Fuel Cell System for Heavy Duty Applications

The motivation for this project was to develop a high-pressure 100+ kW fuel cell stack that can be used in a modular fashion to power HD applications up to 1 MW. One of the issues that was identified during fuel cell system integration was the need for extra space for heat rejection systems(radiators) as well as additional fans and associated energy consumption to compensate for lower operating temperatures of fuel cells compared to internal combustion (IC) engines. To maximize the heat rejection capability of existing water-based coolant systems that are prevalent on IC engine-based systems, fuel cell stack design was developed to withstand and operate at IC engine coolant temperatures or higher, which in turn helps to reduce the radiator size requirement.

08 HYDROGEN↗
DOE OSTI2025

The search for high-entropy fuel-cell catalysts using disorder descriptors

The transition to a hydrogen economy depends on efficient, affordable catalysts for fuel cells. Platinum—the industry standard for fuel-cell electrodes—is costly and scarce, highlighting the need for practical alternatives. High-entropy alloys offer vast compositional diversity and tunable properties that can mitigate these issues, yet their chemical complexity and configurational disorder have hindered rational discovery. Here, we introduce a data-driven framework that couples machine learning with first-principles disorder descriptors—including the entropy forming ability, disordered enthalpy-entropy descriptor, and electronic-structure similarity metrics to platinum—to predict alloy synthesizability and catalytic performance. These descriptors are applied for the first time in the context of fuel-cell catalyst discovery. The workflow rapidly screens more than 20 000 compositions and identifies several platinum-free candidates that are economically viable, readily scalable, and exhibit promising predicted activity. These results demonstrate that disorder descriptors are reliably predicted by machine learning models and can be effectively integrated into materials-discovery pipelines, accelerating innovation across complex compositional spaces.

fuel-cell catalysts↗
NASA NTRS2004

Hydrogen-Oxygen PEM Regenerative Fuel Cell at NASA Glenn Research Center

The NASA Glenn Research Center has constructed a closed-cycle hydrogen-oxygen PEM regenerative fuel cell (RFC) to explore its potential use as an energy storage device for a high altitude solar electric aircraft. Built up over the last 2 years from specialized hardware and off the shelf components the Glenn RFC is a complete "brassboard" energy storage system which includes all the equipment required to (1) absorb electrical power from an outside source and store it as pressurized hydrogen and oxygen and (2) make electrical power from the stored gases, saving the product water for re-use during the next cycle. It consists of a dedicated hydrogen-oxygen fuel cell stack and an electrolyzer stack, the interconnecting plumbing and valves, cooling pumps, water transfer pumps, gas recirculation pumps, phase separators, storage tanks for oxygen (O2) and hydrogen (H2), heat exchangers, isolation valves, pressure regulators, nitrogen purge provisions, instrumentation, and other components. It specific developmental functions include: (1) Test fuel cells and fuel cell components under repeated closed-cycle operation (nothing escapes; everything is used over and over again). (2) Simulate diurnal charge-discharge cycles (3) Observe long-term system performance and identify degradation and loss mechanisms. (4) Develop safe and convenient operation and control strategies leading to the successful development of mission-capable, flight-weight RFC's.

Bents, David J.↗
NASA NTRS2006

Round Trip Energy Efficiency of NASA Glenn Regenerative Fuel Cell System

NASA Glenn Research Center (GRC) has recently demonstrated a Polymer Electrolyte Membrane (PEM) based hydrogen/oxygen regenerative fuel cell system (RFCS) that operated for a charge/discharge cycle with round trip efficiency (RTE) greater than 50 percent. The regenerative fuel cell system (RFCS) demonstrated closed loop energy storage over a pressure range of 90 to 190 psig. In charge mode, a constant electrical power profile of 7.1 kWe was absorbed by the RFCS and stored as pressurized hydrogen and oxygen gas. In discharge mode, the system delivered 3 to 4 kWe of electrical power along with product water. Fuel cell and electrolyzer power profiles and polarization performance are documented in this paper. Individual cell performance and the variation of cell voltages within the electrochemical stacks are also reported. Fuel cell efficiency, electrolyzer efficiency, and the system RTE were calculated from the test data and are included below.

Garcia, Christopher P.↗
DOE OSTI2022

Half-cell electrode assessments of a crossover-tolerant direct methanol fuel cell with a platinum group metal-free cathode

In this work, a platinum group metal- free (PGM-free) Fe-N-C oxygen reduction reaction (ORR) catalyst derived from metal organic framework precursors (Fe-MOF) is evaluated at the cathode side of a direct methanol fuel cell (DMFC). A wide range of methanol concentrations were used, and the performance of the DMFC using air was evaluated and compared to a commercial Pt/C cathode. We conducted our tests with a custom, integrated H 2 reference electrode that separately provided the anode and cathode overpotentials. This allowed us to perform a Tafel analysis on both electrodes and understand the dominant polarizations involved at the PGM-free cathode and the PtRu/C anode. Overall, we achieved a high cell performance using a Fe-N-C based catalyst under liquid methanol and air operation with a peak power density of 111 mW/cm 2 , where the cathode presented a markedly larger contribution to the voltage loss versus the anode. Additionally, we used nanoscale X-ray computed tomography (nano-CT) to image the Fe-N-C cathode and investigate the ionomer and pore size distributions allowing us to identify areas of improvement for catalyst layer fabrication.

30 DIRECT ENERGY CONVERSION↗
NASA NTRS1980

Solid Polymer Electrolyte Fuel Cell Technology Program

Work is reported on phase 5 of the Solid Polymer Electrolyte (SPE) Fuel Cell Technology Development program. The SPE fuel cell life and performance was established at temperatures, pressures, and current densities significantly higher than those previously demonstrated in sub-scale hardware. Operation of single-cell Buildup No. 1 to establish life capabilities of the full-scale hardware was continued. A multi-cell full-scale unit (Buildup No. 2) was designed, fabricated, and test evaluated laying the groundwork for the construction of a reactor stack. A reactor stack was then designed, fabricated, and successfully test-evaluated to demonstrate the readiness of SPE fuel cell technology for future space applications.

Source record↗
NASA NTRS1993

PEM regenerative fuel cells

This paper will update the progress in developing electrocatalyst systems and electrode structures primarily for the positive electrode of single-unit solid polymer proton exchange membrane (PEM) regenerative fuel cells. The work was done with DuPont Nafion 117 in complete fuel cells (40 sq cm electrodes). The cells were operated alternately in fuel cell mode and electrolysis mode at 80 C. In fuel cell mode, humidified hydrogen and oxygen were supplied at 207 kPa (30 psi); in electrolysis mode, water was pumped over the positive electrode and the gases were evolved at ambient pressure. Cycling data will be presented for Pt-Ir catalysts and limited bifunctional data will be presented for Pt, Ir, Ru, Rh, and Na(x)Pt3O4 catalysts as well as for electrode structure variations.

Swette, Larry L.↗
DOE OSTI2023

Natural fiber-derived gas diffusion layers for high performance, lower cost PEM fuel cells

The gas diffusion layer (GDL) is a critical component of proton exchange membrane fuel cells. GDL manufacture is dominated by the use of polyacrylonitrile (PAN) fibers, resulting in high production costs. Those costs contribute to the high cost of fuel cell stacks. Thus, reducing GDL manufacturing costs without sacrificing performance, should help reduce the overall cost of the fuel cell stack. Using inexpensive, natural fiber-based papers and fabric as substrates, here we examine the inherent performance these materials as GDLs, and the improvements enabled by the addition of a microporous layer, gas-phase hydrophobic treatment, and densification. The resulting GDLs achieve equivalent performance the commercial baseline GDL and demonstrate the potential of lower cost GDLs.

25 ENERGY STORAGE↗
DOE OSTI2023

A Goldilocks Approach to Water Management: Hydrochannel Porous Transport Layers for Unitized Reversible Fuel Cells

Abstract This work presents a novel porous transport layer (PTL), the hydrochannel PTL, that enables improved water management and record high round trip efficiency in unitized reversible fuel cells (URFCs). URFCs require rapid transport of O 2 and H 2 O to provide high performance in both fuel cell and water electrolyzer operation, but cell design is complicated by conflicting water management requirements: electrolyzers perform best with high liquid water saturation, whereas fuel cells perform best when liquid water saturation is as low as possible while still maintaining effective ionomer hydration. The hydrochannel PTL circumvents this obstacle by providing hydrophilic channels for water transport through an otherwise hydrophobic PTL, enabling optimal performance in both fuel cell and water electrolyzer modes. Neutron radiography measurements of water content in both operating modes confirm that the hydrochannel PTL enables high performance due to its improved water management capabilities.

25 ENERGY STORAGE↗
DOE OSTI2026

Domestically Manufactured Fuel Cells for Heavy Duty Applications

This project, funded by the U.S. Department of Energy under Award DE-EE0009248, advances the domestic development of fuel-cell stack technologies for heavy-duty transportation applications. The work directly supports the Million-Mile Fuel Cell Truck (M2FCT) initiative by improving performance, durability, and manufacturability—key requirements for next-generation hydrogen fuel-cell systems.

08 HYDROGEN↗
DOE OSTI2022

Understanding the E balance for water management in hydroxide exchange membrane fuel cells

As a key challenge for hydroxide exchange membrane fuel cells (HEMFCs), understanding water management deeply is critical for performance and durability improvement. Here, in this work, we show that the balance between water generation and phase-change-induced (PCI) flow is the main factor controlling cell voltage over a wide range of conditions where the cells are vulnerable to severe flooding. The regulation of flooding by heat generation can be reflected by a stable voltage with increase of current density in the polarization curve. This PCI balance voltage (E balance ), which determines the shape of polarization curve, is modeled as a function of cell operating conditions and gas diffusion layer (GDL) properties. Temperature, pressure, and thermal conductivity of GDL were found important for tuning the level of E balance , both in HEMFCs and proton exchange membrane fuel cells. The understanding of E balance will help to generate strategies for resolving flooding in HEMFCs, and it offers a new perspective for polarization curve interpretation.

25 ENERGY STORAGE↗