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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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All sourcesNASA NTRSDOE OSTI
DOE OSTI2023

Improved Fuel Cell Chemical Durability of an Heteropoly Acid Functionalized Perfluorinated Terpolymer-Perfluorosulfonic Acid Composite Membrane

Commercial proton exchange membrane heavy-duty fuel cell vehicles will require a five-fold increase in durability compared to current state-of-the art light-duty fuel cell vehicles. We describe a new composite membrane that incorporates silicotungstic heteroply acid (HPA), α -K 8 SiW 11 O 40 ▪13H 2 O, a radical decomposition catalyst and when acid-exchanged can potentially conduct protons. The HPA was covalently bound to a terpolymer of tetrafluoroethylene, vinylidene fluoride, and sulfonyl fluoride containing monomer (1,1,2,2,3,3,4,4-octafluoro-4-((1,2,2-trifluorovinyl)oxy)butane-1-sulfonyl fluoride) by dehydrofluorination followed by addition of diethyl (4-hydroxyphenyl) phosphonate, giving a perfluorosulfonic acid-vinylidene fluoride-heteropoly acid (PFSA-VDF-HPA). A composite membrane was fabricated using a blend of the PFSA-VDF-HPA and the 800EW 3M perfluoro sulfonic acid polymer. The bottom liner-side of the membrane tended to have a higher proportion of HPA moieties compared to the air-side as gravity caused the higher mass density PFSA-VDF-HPA to settle. The composite membrane was shown to have less swelling, more hydrophobic properties, and higher crystallinity than the pure PFSA membrane. The proton conductivity of the membrane was 0.130 ± 0.03 S cm −1 at 80 °C and 95% RH. Impressively, when the membrane with HPA-rich side was facing the anode, the membrane survived more than 800 h under accelerated stress test conditions of open-circuit voltage, 90 °C and 30% RH.

08 HYDROGEN↗
DOE OSTI2023

Improving Durability of Fuel Cells with Platinum-rich Alloy Cathode Catalysts

Pt 3 Co-alloy based nanoparticle catalysts are very active for oxygen reduction reaction (ORR) thereby enabling high performance of proton exchange membrane fuel cells (PEMFC) for automotive propulsion. However, these catalyst materials degrade due to a combination of electrochemical surface area (ECSA) loss and dissolution of cobalt-alloying element from the nanoparticles. Dissolution of cobalt has a two-fold impact on the durability of fuel cells—i) a loss in the low-current density kinetic region due to a decrease in specific activity and ii) a loss in the high-current density transport region due to Co 2+ contamination of the ionomer phase. Cobalt dissolution-contamination needs to be mitigated as it limits fuel cell performance and lifetime for heavy-duty automotive applications. In this article, we study the use of PtCo-alloy catalysts with Pt-rich compositions using catalyst-specific accelerated stress test measurement in membrane electrode assemblies to decrease the amount of dissolved Co and mitigate its subsequent contamination effects. We demonstrate Pt 5 Co and Pt 7 Co compositions to enable significant improvements in durability (∼50 mV and ∼100 mV with respect to Pt 3 Co after 30,000 voltage cycles) with a minor but acceptable compromise in the initial specific activity of the catalyst.

08 HYDROGEN↗
DOE OSTI2024

Performance and Durability of Heavy-Duty Fuel Cell Systems with an Advanced Ordered Intermetallic ORR Alloy Catalyst and Novel Support

Ordered PtCo intermetallic (OIM) catalyst (L1 0 -PtCo/C) is a promising candidate as the oxygen reduction reaction (ORR) catalyst in hybrid fuel cell systems (FCS) for class-8 heavy duty (HD) trucks. Compared to a baseline annealed Pt on high surface area carbon (a-Pt/HSC) catalyst, its mass activity (MA) is 71% higher initially and 144% higher after 90,000 potential cycles in an accelerated stress test (AST). Analysis of the AST data indicates that the ORR kinetic constants do not change with aging and the degradation in the OIM catalyst activity is linearly proportional to the loss in the electrochemically active surface area (ECSA). Several operational strategies are investigated to mitigate catalyst degradation and achieve 25,000-h electrode lifetime and 2.5 kW g −1 Pt utilization on a HD truck duty cycle including load sharing with the hybrid battery, regulating the radiator fan power to maintain the coolant temperature close to 60 °C, clipping the maximum cell voltage below 850 mV, limiting the ECSA loss to 55%, and oversizing the active area of the membrane electrode assemblies by 20%. Drive cycle simulations indicate that the lifetime average voltage degradation rate is about 1.8 μV h −1 and the integrated stack and FCS drive cycle efficiencies decrease by 3.5 to 3.9%.

25 ENERGY STORAGE↗
DOE OSTI2026

How Selective Transport Layer Improves Efficiency and Durability of Proton Exchange Membrane Fuel Cells

In any electrochemical device, the separator or membrane allows specific ions to transport but blocks electrons and other chemical species, enabling the electrochemical energy to be harvested. However, small amounts of undesired species are known to permeate through the membrane, reducing overall system efficiency and lifetime. An emerging concept called the “Selective Transport Layer” preferentially allows only protons to pass through but reduces the permeance of other species by a meaningful degree. Here, in this study, we demonstrate that a 60 nm thick graphene oxide composite layer can be very effective in reducing gas and ion permeation, even for a gas as small as H 2 , while not noticeably increasing proton transport resistance. In electrode and membrane accelerated stability tests, we show that both electrode and membrane durability are improved by a factor of two. Microscopy and mathematic simulations confirm that the graphene oxide composite is effective in blocking transport of dissolved Pt 2+ . The improved durability and reduced H 2 fuel crossover are expected to substantially reduce initial and operating costs of the fuel cell system. How this technology may affect other membrane-based electrochemical devices is also discussed.

Ngo, Phuong Quynh [General Motors, Pontiac, MI (Un↗
DOE OSTI2018

Development of a Simple and Rapid Diagnostic Method for Polymer-Electrolyte Fuel Cells

A simple and fast diagnostic tool has been developed for analyzing polymer-electrolyte fuel-cell degradation. The tool is based on analyzing changes in polarization curves of a cell over its lifetime. The shape of the polarization-change curve and its sensitivity to oxygen concentration are found to be unique for each degradation pathway based on analysis from a detailed 2-D numerical model of the cell. Using the polarization-change curve methodology, the primary mechanism for degradation (kinetic, ohmic, and/or transport related) can be identified. Here, the technique is applied to two sets of data to explain performance changes after two different cells undergo voltage-cycling accelerated stress test, where it is found that changes are kinetic and then ohmic or transport in nature depending on the cell type. The diagnostic tool provides a simple method for rapid determination of primary degradation mechanisms. Finally, areas for more detailed future investigations are also summarized.

08 HYDROGEN↗
DOE OSTI2017

Thermochemical Stability Study of Alkyl-Tethered Quaternary Ammonium Cations for Anion Exchange Membrane Fuel Cells

The increased interest in the use of anion exchange membranes (AEMs) for applications in electrochemical devices has prompted significant efforts in designing materials with robust stability in alkaline media. Most reported AEMs suffer from polymer backbone degradation as well as cation functional group degradation. In this report, we provide comprehensive experimental investigations for the analysis of cation functional group stability under alkaline media. A silver oxide-mediated ion exchange method and an accelerated stability test in aqueous KOH solutions at elevated temperatures using a Parr reactor were used to evaluate a broad scope of quaternary ammonium (QA) cationic model compound structures, particularly focusing on alkyl-tethered cations. Additionally, byproduct analysis was employed to gain better understanding of degradation pathways and trends of alkaline stability. Experimental results under different conditions gave consistent trends in the order of cation stability of various QA small molecule model compounds. Overall, cations that are benzyl-substituted or that are near to electronegative atoms (such as oxygen) degrade faster in alkaline media in comparison to alkyl-tethered QAs. These comprehensive model compound stability studies provide valuable information regarding the relative stability of various cation structures and can help guide researchers towards designing new and promising candidates for AEM materials.

25 ENERGY STORAGE↗
DOE OSTI2013

A Semi-Empirical Two Step Carbon Corrosion Reaction Model in PEM Fuel Cells

The cathode CL of a polymer electrolyte membrane fuel cell (PEMFC) was exposed to high potentials, 1.0 to 1.4 V versus a reversible hydrogen electrode (RHE), that are typically encountered during start up/shut down operation. While both platinum dissolution and carbon corrosion occurred, the carbon corrosion effects were isolated and modeled. The presented model separates the carbon corrosion process into two reaction steps; (1) oxidation of the carbon surface to carbon-oxygen groups, and (2) further corrosion of the oxidized surface to carbon dioxide/monoxide. To oxidize and corrode the cathode catalyst carbon support, the CL was subjected to an accelerated stress test cycled the potential from 0.6 VRHE to an upper potential limit (UPL) ranging from 0.9 to 1.4 VRHE at varying dwell times. The reaction rate constants and specific capacitances of carbon and platinum were fitted by evaluating the double layer capacitance (Cdl) trends. Carbon surface oxidation increased the Cdl due to increased specific capacitance for carbon surfaces with carbon-oxygen groups, while the second corrosion reaction decreased the Cdl due to loss of the overall carbon surface area. The first oxidation step differed between carbon types, while both reaction rate constants were found to have a dependency on UPL, temperature, and gas relative humidity.

08 HYDROGEN↗
DOE OSTI2016

Polybenzimidazole (PBI) functionalized nanographene as highly stable catalyst support for polymer Electrolyte membrane fuel cells (PEMFCs)

Nanoscale graphenes were used as cathode catalyst supports in proton exchange membrane fuel cells (PEMFCs). Surface-initiated polymerization that covalently bonds polybenzimidazole (PBI) polymer on the surface of graphene supports enables the uniform distribution of the Pt nanoparticles, as well as allows the sealing of the unterminated carbon bonds usually present on the edge of graphene from the chemical reduction of graphene oxide. The nanographene effectively shortens the length of channels and pores for O 2 diffusion/water dissipation and significantly increases the primary pore volume. Further addition of p-phenyl sulfonic functional graphitic carbon particles as spacers, increases the specific volume of the secondary pores and greatly improves O 2 mass transport within the catalyst layers. The developed composite cathode catalyst of Pt/PBI-nanographene (50 wt%) + SO 3 H-graphitic carbon black demonstrates a higher beginning of life (BOL) PEMFC performance as compared to both Pt/PBI-nanographene (50 wt%) and Pt/PBI-graphene (50 wt%) + SO 3 H-graphitic carbon black (GCB). Accelerated stress tests show excellent support durability compared to that of traditional Pt/Vulcan XC72 catalysts, when subjected to 10,000 cycles from 1.0 V to 1.5 V. As a result, this study suggests the promise of using PBI-nanographene + SO 3 H-GCB hybrid supports in fuel cells to achieve the 2020 DOE targets for transportation applications.

30 DIRECT ENERGY CONVERSION↗
DOE OSTI2017

PERLE – BEAM OPTICS DESIGN

PERLE (Powerful ERL for Experiments) [1] is a novel ERL test facility, initially proposed to validate design choices for a 60 GeV ERL needed for a future extension of the LHC towards a hadron-electron collider, the LHeC [2]. Its main goal is to test the limits of a high current, CW, multi-pass operation with superconducting cavities at 802 MHz (and perhaps exploring other frequencies of interest). PERLE optics features Flexible Momentum Compaction (FMC) lattice architecture for six vertically stacked return arcs and a high current, 5 MeV photo-injector. With only one pair of 4-cavity cryomodules, 400 MeV beam energy can be reached in three re-circulation passes, with beam currents in excess of 15 mA. This unique quality beam is intended to perform a number of experiments in different fields reaching from uncharted tests of accelerator components via elastic ep scattering to laser-Compton backscattering for photon physics [3]. Following the experiment, the CW beam is decelerated in three consecutive passes back to the injection energy, transferring virtually stored energy back to the RF.

Bogacz, S.↗
DOE OSTI2021

Beam Profile Measurements Utilizing an Amplitude Modulated Pulsed Fiber Laser at PIP2IT

Fermilab is undertaking the development of a new 800 MeV superconducting RF linac to replace its present normal conducting 400 MeV linac. The PIP-II linac consists of a warm front-end generating 2 mA of 2.1 MeV H⁻ followed immediately by a series of superconducting RF cryomodules to 800 MeV. To limit the potential damage to the superconducting RF cavities, PIP-II will utilize laser-based monitors to obtain beam profiles via photoionization. This paper will present the results of transverse and longitudinal beam profile measurements using a prototype profile monitor that was tested with 2.1 MeV H⁻ beam at the PIP-II Injector Test (PIP2IT) accelerator. This prototype profile monitor utilizes a high repetition rate fiber laser and fiber optic transport into the PIP2IT enclosure. In addition, results will be shown of narrow-band electron detection from amplitude modulated laser pulses.

43 PARTICLE ACCELERATORS↗
DOE OSTI2018

Update on Plasma Processing R&D for LCLS-II

SRF cavities performance preservation is crucial, from vertical test to accelerator operation. Field emission is still one of the main problems to overcome and plasma cleaning has been proven successful by SNS, in cleaning field emitters and increasing the work function of Nb. A collaboration has been established between FNAL, SLAC and ORNL with the purpose of applying plasma processing to LCLS-II cavities, in order to minimize and overcome field emission without affecting the high Q of N-doped cavities. The recipe will follow the neon-oxygen active plasma adopted at SNS, allowing in-situ processing of cavities and cryomodules from hydrocarbon contaminants. A novel method for plasma ignition has been developed at FNAL: a plasma glow discharge is ignited using high order modes to overcome limitations imposed by the fundamental power coupler. The results of experiments on 9-cell LCLS-II cavity are presented, along with plasma ignition studies. In addition the RF system is shown and N-doped Nb samples studies are discussed.

43 PARTICLE ACCELERATORS↗
DOE OSTI2024

Impact of Solenoid Induced Residual Magnetic Fields on The Prototype SSR1 CM Performance

A prototype cryomodule containing eight Single Spoke Resonators type-1 (SSR1) operating at 325 MHz and four superconducting focusing lenses was successfully assembled, cold tested, and accelerated beam in the framework of the PIP-II project at Fermilab. The impact of induced residual magnetic fields from the solenoids on performance of cavities is presented in this contribution. In addition, design optimizations for the production cryomodules as a result of this impact are highlighted.

43 PARTICLE ACCELERATORS↗
DOE OSTI2023

Sulfur poisoning mechanism of LSCF cathode material in the presence of SO 2 : a computational and experimental study

Aiming at the comprehensive understanding of the single sulfur poisoning effect and, eventually, the multiple impurities poisoning phenomena on the SOFC (Solid Oxide Fuel Cell) cathode materials, the sulfur poisoning effect on the (La 0.6 Sr 0.4 ) 0.95 Co 0.2 Fe 0.8 O 3 (LSCF-6428) has been investigated in the presence of 10 ppm SO 2 at 800, 900, and 1000°C, respectively, with a combined computational and experimental approach. The good agreement between the CALPHAD (Computer Coupling of Phase Diagrams and Thermochemistry) simulations and the XRD (X-Ray Diffraction), SEM (Scanning Electron Microscopy), and TEM (Transmission Electron Microscopy) characterization results support the reliability of the CALPHAD approach in the SOFC field. Furthermore, comprehensive simulations were made to understand the impact of temperature, P(SO 2 ), P(O 2 ), and Sr concentration on the threshold of SrSO 4 stability. Results showed that the formation of SrSO4 is thermodynamically favored at lower temperatures, higher P(SO 2 ), higher P(O 2 ), and higher Sr concentration. Finally, comparisons were also made between LSCF-6428 and LSM20 (La 0.8 Sr 0.2 MnO 3 ) using simulations, which confirmed that LSCF-6428 is a poor sulfur-tolerant cathode, in agreement with the literature.

36 MATERIALS SCIENCE↗
DOE OSTI2011

Sustainable LED Fluorescent Light Replacement Technology

Ilumisys and the National Center for Manufacturing Sciences (NCMS) partnered on a three-year project awarded by the United States (U.S.) Department of Energy (DOE), to quantify the impacts of LED lamps, incandescent lamps and fluorescent benchmark lamps over a product lifecycle – i.e. to develop a sustainable design and manufacturing strategy that addresses product manufacturing, use, recycling and disposal scenarios for LED-based lighting. Based on the knowledge gained from extensive product tear-down studies of fluorescent and screw-in lighting products, lifecycle assessment tools, and accelerated lifecycle testing protocols, an interactive Sustainable LED Design Guide has been developed to aid architectural and lighting designers and engineers in making design decisions that consider three important environmental impacts (greenhouse gas emissions, energy use and mercury emission) across all phases of the life of an LED lighting product. Critical information developed for the lifecycle analysis and product feature comparisons is the useful life of the lighting product as well as its performance. The Design Guide is available at www.ncms.org, and was developed based on operational and durability testing of a variety of lighting products including power consumption, light output, and useful life of a lamp in order to allow a more realistic comparison of lamp designs. This report describes the main project tasks, results and innovative features of the lifecycle assessment (LCA)-based design tools, and the key considerations driving the sustainable design of LED lighting systems. The Design Guide incorporates the following three novel features for efficiently evaluating LED lighting features in value-chains: Bill-of-Materials (BOM) Builder – Designers may import process data for each component and supply functional data for the product, including power, consumption, lumen output and expected useful life: Environmental Impact Review – Designs are comparable across lifecycle phases, subsystems, and environmental impact category, and can be normalized to a user-defined functional unit: Drill-down Review – These provide an in-depth look at individual lamp designs with the ability to review across subsystem or lifecycle phase.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2015

Kinetics of Chronic Oxidation of NBG-17 Nuclear Graphite by Water Vapor

This report presents the results of kinetic measurements during accelerated oxidation tests of NBG-17 nuclear graphite by low concentration of water vapor and hydrogen in ultra-high purity helium. The objective is to determine the parameters in the Langmuir-Hinshelwood (L-H) equation describing the oxidation kinetics of nuclear graphite in the helium coolant of high temperature gas-cooled reactors (HTGR). Although the helium coolant chemistry is strictly controlled during normal operating conditions, trace amounts of moisture (predictably < 0.2 ppm) cannot be avoided. Prolonged exposure of graphite components to water vapor at high temperature will cause very slow (chronic) oxidation over the lifetime of graphite components. This behavior must be understood and predicted for the design and safe operation of gas-cooled nuclear reactors. The results reported here show that, in general, oxidation by water of graphite NBG-17 obeys the L-H mechanism, previously documented for other graphite grades. However, the characteristic kinetic parameters that best describe oxidation rates measured for graphite NBG-17 are different than those reported previously for grades H-451 (General Atomics, 1978) and PCEA (ORNL, 2013). In some specific conditions, certain deviations from the generally accepted L-H model were observed for graphite NBG-17. This graphite is manufactured in Germany by SGL Carbon Group and is a possible candidate for the fuel elements and reflector blocks of HTGR.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2016

Status of Chronic Oxidation Studies of Graphite

Graphite will undergo extremely slow, but continuous oxidation by traces of moisture that will be present, albeit at very low levels, in the helium coolant of HTGR. This chronic oxidation may cause degradation of mechanical strength and thermal properties of graphite components if a porous oxidation layer penetrates deep enough in the bulk of graphite components during the lifetime of the reactor. The current research on graphite chronic oxidation is motivated by the acute need to understand the behavior of each graphite grade during prolonged exposure to high temperature chemical attack by moisture. The goal is to provide the elements needed to develop predictive models for long-time oxidation behavior of graphite components in the cooling helium of HTGR. The tasks derived from this goal are: (1) Oxidation rate measurements in order to determine and validate a comprehensive kinetic model suitable for prediction of intrinsic oxidation rates as a function of temperature and oxidant gas composition; (2) Characterization of effective diffusivity of water vapor in the graphite pore system in order to account for the in-pore transport of moisture; and (3) Development and validation of a predictive model for the penetration depth of the oxidized layer, in order to assess the risk of oxidation caused damage of particular graphite grades after prolonged exposure to the environment of helium coolant in HTGR. The most important and most time consuming of these tasks is the measurement of oxidation rates in accelerated oxidation tests (but still under kinetic control) and the development of a reliable kinetic model. This report summarizes the status of chronic oxidation studies on graphite, and then focuses on model development activities, progress of kinetic measurements, validation of results, and improvement of the kinetic models. Analysis of current and past results obtained with three grades of showed that the classical Langmuir-Hinshelwood model cannot reproduce all data collected so far. Starting from here we propose a modification of the LH model to include temperature activation of graphite surface as a Boltzmann activation function. The enhanced Boltzmann-Langmuir-Hinshelwood model (BLH) was tested successfully on three grades of graphite. The model is a robust, comprehensive mathematical function that allows better fitting of experimental results spanning a wide range of temperature and partial pressures of water vapor and hydrogen. However, the model did not fit satisfactorily the data extracted from the old report on graphite H-451 oxidation by water.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2017

Materials and Designs for High-Efficacy LED Light Engines

Cree, Inc. conducted a narrow-band downconverter (NBD) materials development and implementation program which will lead to warm-white LED light engines with enhanced efficacy via improved spectral efficiency with respect to the human eye response. New red (600-630nm) NBD materials could result in as much as a 20% improvement in warm-white efficacy at high color quality relative to conventional phosphor-based light sources. Key program innovations included: high quantum yield; narrow peak width; minimized component-level losses due to “cross-talk” and light scattering among red and yellow-green downconverters; and improved reliability to reach parity with conventional phosphors. NBD-enabled downconversion efficiency gains relative to conventional phosphors yielded an end-of-project LED light engine efficacy of >160 lm/W at room temperature and 35 A/cm2, with a correlated color temperature (CCT) of ~3500K and >90 CRI (Color Rending Index). NBD-LED light engines exhibited equivalent luminous flux and color point maintenance at >1,000 hrs. of highly accelerated reliability testing as conventional phosphor LEDs. A demonstration luminaire utilizing an NBD-based LED light engine had a steady-state system efficacy of >150 lm/W at ~3500K and >90 CRI, which exceeded the 2014 DOE R&D Plan luminaire milestone for FY17 of >150 lm/W at just 80 CRI.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗