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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 91 records · Page 5
All sourcesNASA NTRSDOE OSTI
DOE OSTI2025

Optimizing Hybrid-Phase IrO2 Catalysts with Ti for Enhanced Oxygen Evolution Reaction for Proton Exchange Membrane Water Electrolysis

To realize a sustainable energy transition, water electrolysis-particularly proton exchange membrane water electrolysis (PEMWE)-holds significant promise. However, practical deployment is hindered by the cost and instability of the anode catalyst, IrO2. Recent studies indicate that tuning the Ir-O bond distance, via doping or composite formation, is key to enhancing the oxygen evolution reaction (OER) performance of IrO2-based electrocatalysts. Herein, a hybrid-phase Ti-incorporated IrO2 electrocatalyst is developed, exhibiting outstanding OER activity (298.8 mV at 100 mA cm-2) and stability over 25 h. This improvement originates from asymmetric interatomic interactions introduced by Ti, as revealed by combined experimental X-ray analyses and theoretical modeling. Ti incorporation induces tensile strain along the z-axis in IrO2 motifs, effectively reducing the average Ir-O bond distance and thereby enhancing OER activity. In situ X-ray absorption spectroscopy further confirms that at 1.5 V (vs. RHE), the elongated Ir-O bond facilitates -OOH* intermediate formation while suppressing Ir dissolution, contributing to superior stability. These findings underscore the critical role of Ir-O bond engineering in balancing activity and durability, offering strategic insights for the rational design of high-performance OER catalysts for renewable energy technologies.

08 HYDROGEN↗
DOE OSTI2025

Effect of cell compression on the performance and the structure of proton exchange membrane water electrolyzer (PEMWE) assembly

Here, in the field of water electrolysis, the proton exchange membrane water electrolyzer (PEMWE) is currently the most advanced technology for producing hydrogen without emitting CO 2 . Although PEMWE plants are already in operation, further research is needed to improve cell efficiency and reduce the use of rare materials, such as iridium oxide catalysts for the oxygen evolution reaction (OER). One of the main causes of performance loss in PEMWE is the relatively low electric conductivity of the porous transport layer (PTL) and of the anode catalyst layer, which results in ohmic losses and low catalyst utilization during high current density operation. The objective of this study is to investigate how optimization of the PTL and electrode interface can increase the cell performance. To this end, we tested different cell assemblies using fibrous and sintered PTLs, decreasing membrane thickness, reducing iridium loading, and inserting a microporous layer to increase contact surface area. Electrochemical characterization of each cell configuration was systematically performed at various compression levels as the pressure is a crucial parameter influencing the electrode/PTL contact area. In parallel, X-ray microcomputed tomography (micro-CT) was employed to investigate the effects of cell hydration and compression on the structure of PEMWE components. This study combining electrochemistry and micro-CT imaging presents how optimizing the electrode/PTL contact surface area, minimizes ohmic losses, and enables PEMWE operation with low iridium loading at high current densities.

Catalyst - PTL interface↗
DOE OSTI2026

Impact of Porous Transport Layer Morphology on the Performance of Proton Exchange Membrane Water Electrolyzers with Ultra-Low Iridium Loadings

Reducing Ir loadings in proton exchange membrane water electrolyzer anodes is critical for lowering capital expenses. Loading reduction could be achieved by improving the Ir activity via doping/alloying and/or the development of advanced microstructures. However, the anode porous transport layer (PTL) is a comparatively simple component whose properties also impact Ir utilization. Therefore, well-designed PTLs may also enable reduced Ir loadings. In this work, we survey eight PTLs from various manufacturers to observe their impact on cell performance at low (0.4 mg Ir cm -2 ) and ultralow (0.1 mg Ir cm -2 ) Ir loadings. The PTLs were characterized by their microstructural properties, including porosity, particle size distribution, and pore size distribution. Electrochemical cell performance was correlated to PTL morphology, and it was found that PTLs with lower porosities and smaller particle and pore radii enabled good performance even at ultralow Ir loadings. 1000-h durability testing indicated that using lower porosity PTLs can significantly improve durability behavior. A runaway voltage phenomenon was observed during durability testing of cells with ultralow Ir loadings, which was caused by increases in both anode and cathode overpotentials. Furthermore, we observed that the beginning of test performance of 0.1 mg Ir cm -2 cells correlates to the 1000-h degradation rates of 0.4 mg Ir cm -2 cells, suggesting that for the Ir catalyst used in this work, short-term testing at ultralow loadings can be used as an indicator of long-term degradation at higher loadings.

08 HYDROGEN↗
DOE OSTI2023

Rational Materials and Structure Design for Improving the Performance and Durability of High Temperature Proton Exchange Membranes (HT-PEMs)

Hydrogen energy as the next-generation clean energy carrier has attracted the attention of both academic and industrial fields. A key limit in the current stage is the operation temperature of hydrogen fuel cells, which lies in the slow development of high-temperature and high-efficiency proton exchange membranes. Currently, much research effort has been devoted to this field, and very innovative material systems have been developed. The authors think it is the right time to make a short summary of the high-temperature proton exchange membranes (HT-PEMs), the fundamentals, and developments, which can help the researchers to clearly and efficiently gain the key information. In this paper, the development of key materials and optimization strategies, the degradation mechanism and possible solutions, and the most common morphology characterization techniques as well as correlations between morphology and overall properties have been systematically summarized.

08 HYDROGEN↗
DOE OSTI2021

Recent advances in integrating platinum group metal-free catalysts in proton exchange membrane fuel cells

Platinum group metal (PGM)-free catalysts are promising low-cost materials for the oxygen reduction reaction in proton exchange membrane fuel cells (PEMFCs). A variety of chemical precursors and synthesis methods have been proposed to increase their catalytic activity. In comparison, significantly less attention has been dedicated to the integration of these PGM-free catalysts into operating electrodes by investigating the role of the membrane electrode assembly (MEA) fabrication on the PEMFC performance. Here, we discuss here some remarkable performance improvements recently achieved by tuning catalyst loading, ionomer content, and ink solvent composition, and call for further explorations of the ink processing and MEA fabrication to improve performance.

25 ENERGY STORAGE↗
DOE OSTI2025

Using X-ray radiography to study oxygen flow in a proton exchange membrane electrolyzer operating under balanced pressure conditions

Of the various water electrolyzer technologies, the proton exchange membrane electrolyzer (PEMWE) is one of the best solutions for producing clean hydrogen without releasing CO 2 . In order to allow for widespread use of clean hydrogen, it is necessary to decrease its cost, which is intrinsically related to system operation. Current PEMWE plants operate in differential mode, directly pressurizing hydrogen and benefiting from thermodynamic compression, which increases overall system efficiency. However, high differential pressure above 30 bar can cause membrane stress, resulting in membrane creeping and failure. Pressurizing the water and operating at balanced pressure allows hydrogen to be produced at higher pressures while preserving the integrity of the membrane and porous layers. Nevertheless, the impact of pressurizing water on PEMWE performance must be better understood to maximize performance under balanced pressure conditions. Here, this study examined the impact of water pressure on two-phase flow. A high-pressure electrolyzer setup was developed to perform operando X-ray radiography and examine oxygen transport with high temporal resolution. The imaging segmentation process, developed to capture bubble properties in the channel, was applied to a specific experiment. The results clearly showed that as pressure increased up to 30 bars, the initial bubbly flow transitioned to slug flow, which led to channel saturation with oxygen. This work demonstrates that two-phase flow in an electrolyzer can be studied using X-ray radiography, which has the advantages of fast measurements and the ability to probe dense materials, such as those required for pressurized electrolyzers.

Balanced high pressure operation↗
DOE OSTI2022

Non-iridium-based electrocatalyst for durable acidic oxygen evolution reaction in proton exchange membrane water electrolysis

Iridium-based electrocatalysts remain the only practical anode catalysts for proton exchange membrane (PEM) water electrolysis, due to their excellent stability under acidic oxygen evolution reaction (OER), but are greatly limited by their high cost and low reserves. Here, in this study, we report a nickel-stabilized, ruthenium dioxide (Ni-RuO 2 ) catalyst, a promising alternative to iridium, with high activity and durability in acidic OER for PEM water electrolysis. While pristine RuO 2 showed poor acidic OER stability and degraded within a short period of continuous operation, the incorporation of Ni greatly stabilized the RuO 2 lattice and extended its durability by more than one order of magnitude. When applied to the anode of a PEM water electrolyser, our Ni-RuO 2 catalyst demonstrated >1,000 h stability under a water-splitting current of 200 mA cm -2 , suggesting potential for practical applications. Density functional theory studies, coupled with operando differential electrochemical mass spectroscopy analysis, confirmed the adsorbate-evolving mechanism on Ni-RuO 2 , as well as the critical role of Ni dopants in stabilization of surface Ru and subsurface oxygen for improved OER durability.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
NASA NTRS2011

Proton Exchange Membrane Fuel Cell Engineering Model Powerplant. Test Report: Benchmark Tests in Three Spatial Orientations

Proton exchange membrane (PEM) fuel cell technology is the leading candidate to replace the aging alkaline fuel cell technology, currently used on the Shuttle, for future space missions. This test effort marks the final phase of a 5-yr development program that began under the Second Generation Reusable Launch Vehicle (RLV) Program, transitioned into the Next Generation Launch Technologies (NGLT) Program, and continued under Constellation Systems in the Exploration Technology Development Program. Initially, the engineering model (EM) powerplant was evaluated with respect to its performance as compared to acceptance tests carried out at the manufacturer. This was to determine the sensitivity of the powerplant performance to changes in test environment. In addition, a series of tests were performed with the powerplant in the original standard orientation. This report details the continuing EM benchmark test results in three spatial orientations as well as extended duration testing in the mission profile test. The results from these tests verify the applicability of PEM fuel cells for future NASA missions. The specifics of these different tests are described in the following sections.

Loyselle, Patricia↗
DOE OSTI2024

Constructing Highly Porous Low Iridium Anode Catalysts Via Dealloying for Proton Exchange Membrane Water Electrolyzers

Iridium (Ir) is the most active and durable anode catalyst for the oxygen evolution reaction (OER) for proton exchange membrane water electrolyzers (PEMWEs). However, their large-scale applications are hindered by high costs and scarcity of Ir. Lowering Ir loadings below 1.0 mgcm -2 causes significantly reduced PEMWE performance and durability. Therefore, developing efficient low Ir-based catalysts is critical to widely commercializing PEMWEs. Herein, an approach is presented for designing porous Ir metal aerogel (MA) catalysts via chemically dealloying IrCu alloys. In this study, the unique hierarchical pore structures and multiple channels of the Ir MA catalyst significantly increase electrochemical surface area (ECSA) and enhance OER activity compared to conventional Ir black catalysts, providing an effective solution to design low-Ir catalysts with improved Ir utilization and enhanced stability. An optimized membrane electrode assembly (MEA) with an Ir loading of 0.5 mg Ir cm -2 generated 2.0 A cm -2 at 1.79 V, higher than the Ir black at a loading of 2.0 mg Ir cm -2 (1.63 A cm -2 ). The low-Ir MEA demonstrated an acceptable decay rate of ≈40 µV h -1 during durability tests at 0.5 (>1200 h) and 2.0 A cm -2 (400 h), outperforming the commercial Ir-based MEA (175 µV h -1 at 2.0 mg Ir cm -2 ).

36 MATERIALS SCIENCE↗
DOE OSTI2020

Durable hybrid electrocatalysts for proton exchange membrane fuel cells

The low durability of carbon-based non-precious metal electrocatalysts hinders their practical applications in proton exchange membrane fuel cells (PEMFCs). In this study, we rationally design a hybrid Pt-Fe-N-C electrocatalyst with unprecedented durability. It consists of abundant Pt and Fe single atoms homogeneously dispersed on the nitrogen-doped carbon support and a small amount of Pt-Fe alloy nanoparticles. A PEMFC with Pt-Fe-N-C as the cathode shows a larger peak power density (0.75 W cm -2 ) than that with Fe-N-C as the cathode (0.50 W cm -2 ). The remarkable durability of Pt-Fe-N-C is reflected from no noticeable drop in the half-wave potential after 70000 potential cycles between 0.6 and 1.0 V in the liquid cell, and 80% current retention after 85 h of potential hold at 0.4 V in the fuel cell. This work demonstrates the feasibility of improving the durability of Fe-N-C material via ultra-low Pt doping and makes non-precious metal electrocatalysts be close to achieving commercial metrics.

25 ENERGY STORAGE↗
NASA NTRS1994

Proton exchange membrane fuel cells for space and electric vehicle applications: From basic research to technology development

The proton exchange membrane fuel cell (PEMFC) is one of the most promising electrochemical power sources for space and electric vehicle applications. The wide spectrum of R&D activities on PEMFC's, carried out in our Center from 1988 to date, is as follows (1) Electrode Kinetic and Electrocatalysis of Oxygen Reduction; (2) Optimization of Structures of Electrodes and of Membrane and Electrode Assemblies; (3) Selection and Evaluation of Advanced Proton Conducting Membranes and of Operating Conditions to Attain High Energy Efficiency; (4) Modeling Analysis of Fuel Cell Performance and of Thermal and Water Management; and (5) Engineering Design and Development of Multicell Stacks. The accomplishments on these tasks may be summarized as follows: (1) A microelectrode technique was developed to determine the electrode kinetic parameters for the fuel cell reactions and mass transport parameters for the H2 and O2 reactants in the proton conducting membrane. (2) High energy efficiencies and high power densities were demonstrated in PEMFCs with low platinum loading electrodes (0.4 mg/cm(exp 2) or less), advanced membranes and optimized structures of membrane and electrode assemblies, as well as operating conditions. (3) The modeling analyses revealed methods to minimize mass transport limitations, particularly with air as the cathodic reactant; and for efficient thermal and water management. (4) Work is in progress to develop multi-kilowatt stacks with the electrodes containing low platinum loadings.

Srinivasan, Supramaniam↗
DOE OSTI2025

Performance and Durability Investigation of Thin, Low Crossover Proton Exchange Membranes for Water Electrolyzers

The goal of this project was to fabricate and study the performance and durability implications of thin, mechanically reinforced membranes containing gas recombination catalysts (GRCs) for advanced proton exchange membrane water electrolysis (PEMWE) systems. The thinner membranes, optimized for a PEMWE environment, dramatically reduced the proton transport resistance across the membrane, improving the overall efficiency of the PEMWE system. At the same time, the GRC technology was deployed to recombine crossover hydrogen from the cathode with oxygen from the anode to form water within the membrane. This reaction mitigated the buildup of hydrogen in the oxygen stream, ensuring safe operation of the PEMWE system. Capabilities to measure the gas crossover in both an ex-situ screening cell and in operando application testing were developed over the course of the project to track membrane progress and quantify deliverables. State of the art roll to roll manufacturing technologies were leveraged to fabricate the membranes on a commercial scale, where the membrane structure was precisely tuned and GRC distributed within the membrane structure.

08 HYDROGEN↗
DOE OSTI2026

Optimizing Porous Transport Layer Porosity for Proton Exchange Membrane Water Electrolysis

An empirical model is presented that describes anode-side losses related to porous transport layer (PTL) morphology in proton exchange membrane water electrolysis (PEMWE). The model is based on an advanced voltage breakdown analysis that links various overpotentials to PTL morphology. Custom Ti PTLs, spanning uncommonly low porosities (22 - 31%), were fabricated and analyzed with X-ray CT to obtain pore and particle size distributions. Particle size distributions were consistent across samples with an average particle diameter of 12.0?..mu..m, whereas average pore diameters ranged from 6.0 to 7.0?..mu..m. The PTLs were tested in standard PEMWE cell assemblies with anode catalyst loadings of 0.1 mgIr cm-2 to obtain polarization curves, electrochemical impedance spectra, and augmented Tafel analysis. The PTL-dependent anode side losses were deconvoluted and assigned to excess utilization, concentration, ion transport resistance, and electrical contact resistance overpotentials. The data and model reveal an optimal 20 - 28% PTL porosity region where utilization and contact resistance overpotentials are minimized without triggering concentration and ion transport losses related to water deprivation. The optimal PTL porosity depends on the operating current density and is demonstrated at realistic PEMWE water flow rates to establish PTL design guidance for operation at scale.

08 HYDROGEN↗
DOE OSTI2025

Reversible Losses in Proton Exchange Membrane Water Electrolysis

Lower anode catalyst loadings and higher current densities are essential to lowering the levelized cost of H 2 production via proton exchange membrane water electrolysis (PEMWE). However, these approaches can induce significant durability challenges. Here, we show that cell degradation can include large reversible voltage losses across a variety of conditions, including low loadings and high currents. Although there is limited published discussion of reversible voltage losses in PEMWE, we demonstrate that they are an important consideration in cell efficiency and durability. Understanding the mechanisms of reversible losses and developing mitigation strategies is therefore a key priority for enabling low-cost PEMWE.

08 HYDROGEN↗
DOE OSTI2021

A comprehensive modeling method for proton exchange membrane electrolyzer development

Hydrogen attracts significant interests as an effective energy carrier that can be derived from renewable sources. Hydrogen production using a proton-exchange membrane (PEM) electrolyzer can efficiently convert renewable power via water splitting in wide scales—from large, centralized generation to on-site production. Mathematical models with multiple scales and fidelities facilitate the continuing improvements of PEM electrolyzer development to improve performance, cost, and reliability. The model scopes and methods are presented in this paper, which also introduces a comprehensive PEM electrolysis modeling tool based on computational fluid dynamics (CFD) software, ANSYS/Fluent. The modeling tool incorporates electrochemical model of a PEM electrolysis cell to simulate the performance of coupled thermal-fluid, species transport, and electrochemical processes in a product-scale cell or stack by leveraging the powerful meshing generation and CFD solver of ANSYS/Fluent. The thermal-fluid modeling includes liquid water/gas two-phase flow and simulates a PEM electrolysis cell by using Fluent user-defined functions as add-on modules accounting for PEM-specific species transport and electrochemical processes. The modeling outcomes expediate PEM electrolyzer scaling up from basic material development and laboratory testing.

08 HYDROGEN↗
NASA NTRS1991

Development of a proton-exchange membrane electrochemical reclaimed water post-treatment system

A single-cell electrochemical reactor that utilizes a proton exchange membrane (PEM) as a solid electrolyte is being investigated for posttreatment of reclaimed waste waters with low or negligible electrolyte content. Posttreatment is a final 'polishing' of reclaimed waste waters prior to reuse, and involves removing organic impurities at levels as high as 100 ppm to below 500 ppb total organic carbon (TOC) content to provide disinfection. The system does not utilize or produce either expendable hardware components or chemicals and has no moving parts. Test data and kinetic analysis are presented. The feasibility and application for water reclamation processes in controlled ecological environments (e.g., lunar/Mars habitats) are also presented. Test results show that the electrochemical single cell reactor provides effective posttreatment.

Kaba, Lamine↗
NASA NTRS2000

Analysis and Test of a Proton Exchange Membrane Fuel Cell Power System for Space Power Applications

An effort is underway to develop a prototype Proton Exchange Membrane (PEM) Fuel Cell breadboard system for fuhlre space applications. This prototype will be used to develop a comprehensive design basis for a space-rated PEM fuel cell powerplant. The prototype system includes reactant pressure regulators, ejector-based reactant pumps, a 4-kW fuel cell stack and cooling system, and a passive, membranebased oxygen / water separator. A computer model is being developed concurrently to analytically predict fluid flow in the oxidant reactant system. Fuel cells have historically played an important role in human-rated spacecraft. The Gemini and Apollo spacecraft used fuel cells for vehicle electrical power. The Space Shuttle currently uses three Alkaline Fuel Cell Powerplants (AFCP) to generate all of the vehicle's 15-20kW electrical power. Engineers at the Johnson Space Center have leveraged off the development effort ongoing in the commercial arena to develop PEM fuel cel ls for terrestrial uses. The prototype design originated from efforts to develop a PEM fuel cell replacement for the current Space Shuttle AFCP' s. In order to improve on the life and an already excellent hi storical record of reliability and safety, three subsystems were focused on. These were the fuel cell stack itself, the reactant circulation devices, and reactant / product water separator. PEM fuel cell stack performance is already demonstrating the potential for greater than four times the useful life of the current Shuttle's AFCP. Reactant pumping for product water removal has historically been accomplished with mechanical pumps. Ejectors offer an effective means of reactant pumping as well as the potential for weight reduction, control simplification, and long life. Centrifugal water separation is used on the current AFCP. A passive, membrane-based water separator offers compatibility with the micro-gravity environment of space, and the potential for control simplification, elimination of moving parts in an oxygen environment, and long life. The prototype system has been assembled from components that have previously been tested and evaluated at the component level. Preliminary data obtained from tests performed with the prototype system, as well as other published data, has been used to validate the analytical component models. These components have been incorporated into an integrated oxidant fluid system model. Results obtained from both the performance tests and the analytical model are presented.

Vasquez, Arturo↗