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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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7 records
All sourcesNASA NTRSDOE OSTI
DOE OSTI2024

Durability of Highly Active PGM Catalyst MEA Tested Via Nitrogen and Air AST Cycling Under HDV Condition

PEMFCs are widely considered as the most promising power sources, particularly for heavy-duty vehicles (HDVs). Unfortunately, the degradation of MEAs under HDV condition remains insufficiently studied. In this work, we systematically investigated two MEAs with catalysts of Pt nanoparticles (NPs) supported over high surface area carbon black. These MEAs were tested for durability under HDV condition in nitrogen using a DOE AST protocol for 180,000 cycles, which is equivalent to 30,000 hours or 1 million miles of operation. The commercial Catalyst MEA also underwent 6,000 AST cycles in air under M2FCT condition. We comprehensively investigated the degradation of catalysts. Our results indicate that both MEAs undergo continuous performance degradation in H 2 /air and H 2 /O 2 during the AST cycling in nitrogen, where analysis employing scanning transmission electron microscopy (STEM) and inductively coupled plasma mass spectrometry (ICP-MS) reveal significant degradation behavior for Pt catalysts. The MEA exhibits more significant degradation, especially within mass transfer region, during the AST process in air. In conclusion, this study describes the long-term degradation behavior and mechanism with AST cycling in nitrogen or air governing highly efficient and durable PGM-catalyst MEA design under HDV conditions.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2024

Comparative Evaluation of Control-Oriented Heavy Duty Vehicle Air Drag Coefficient Models

Heavy-duty vehicles (HDVs) are a significant source of fuel consumption and greenhouse gas emissions, prompting solutions such as HDV platooning to mitigate these negative impacts through air drag reduction. The intervehicle distance in an HDV platoon needs to be carefully selected, such that the platoon-level energy efficiency and safety considerations can be well balanced. Underlying this problem lies in accurately modeling the relationship between HDV air drag coefficient and intervehicle distance. Through comprehensive evaluation and comparison, we analyze five control-oriented HDV air drag coefficient models, including the polynomial model, rational polynomial model, rational model, semi-quadratic model, and ridge model. Leveraging Scipy Curve-Fit toolbox and our previously compiled air drag coefficient datasets, we optimally identify the parameters inside each model. The calibrated models are then thoroughly evaluated via five complementary metrics. The comparison results reveal that the semi-quadratic model has the highest overall performance, while the widely adopted rational model only exhibits suboptimal performance.

Best, Micah↗
DOE OSTI2025

Durability of PGM catalyst MEAs of polymer electrolyte membrane fuel cells for heavy-duty vehicles

Polymer electrolyte membrane fuel cells (PEMFCs) are promising power sources for heavy-duty vehicles (HDVs) owing to cleanliness and efficiency. However, the degradation of membrane electrode assemblies (MEAs) under HDV conditions remains a huge challenge. Here, this work investigated MEA durability under HDV conditions using a US Department of Energy standard accelerated stress test for 180,000 cycles (equivalent to 1 million miles of HDV operation). Effects of catalyst Pt content on MEA durability were examined using homemade 30% Pt/C (H-Pt/C) and commercial 46% Pt/C (C-Pt/C) catalysts. Both MEAs experienced H 2 /air and H 2 /O 2 performance loss over cycles. Analysis with scanning transmission electron microscopy, X-ray diffraction, inductively coupled plasma mass spectrometry, and mercury intrusion porosimetry revealed severe degradation of Pt nanoparticles (NPs), support structures, and the catalyst layer. Two degradation stages for NPs were proposed: Ostwald ripening dominated the initial 60,000 cycles, followed by combined Ostwald ripening and particle migration. Measurements with ion chromatography, high-frequency resistance, and oxygen-diffusion resistance revealed degradation of membrane and ionomer, respectively.

25 ENERGY STORAGE↗
DOE OSTI2026

Sparsely Dispersed CeO x ‑Stabilized Pt Nanoparticles Overcome Pt Loading–Durability Trade-Off for Highly Durable Heavy-Duty Fuel Cells

Proton-exchange-membrane fuel cells (PEMFCs) are clean and sustainable mobile power sources for transportation. Recently, their deployment in heavy-duty vehicles (HDVs) has attracted growing interest owing to their high energy scalability and lower infrastructure requirements. However, to meet the stringent requirements for efficiency and long-term durability for HDV applications, PEMFCs typically employ a relatively high platinum group metal (PGM) loading (>0.2 mg PGM /cm 2 ). This elevated PGM loading significantly increases the stack and system costs, surpassing the U.S. Department of Energy (DOE) target of $\$ 60$/kW for commercial viability. Reducing PGM loading while maintaining performance and durability remains a central challenge for HDV fuel cells. Here we exploit metal oxide–Pt interactions and utilize the strong CeO x –Pt interaction to design a CeO x @Pt catalyst structure with exceptional durability. At a low total PGM loading (0.1 mg PGM /cm 2 ), the CeO x @Pt/C catalyst demonstrates high fuel cell performance (8.8 kW/g PGM ) and stability (power retention >90%) after the challenging HDV durability testing (90,000 accelerated-stress-test cycles). With the CeO x @Pt/C catalyst, we showcase over 70% reduction in Pt cost from the M2FCT target (to $\$ 9$/kW), highlighting its promising potential for enabling stable and cost-effective fuel cell systems for heavy-duty applications.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2025

Creating Favorable Pt/Co Interfaces via a Two‐Step Approach for Constructing Highly Durable PtCo Intermetallic Fuel Cell Catalysts

Structurally ordered PtCo intermetallics are one of the most promising oxygen-reduction catalysts in proton exchange membrane fuel cells (PEMFCs) due to their intrinsically improved catalytic activity and stability relative to PtCo solid-solution alloys. However, increasing the heating temperature to achieve a desirable high degree of ordering results in severe particle agglomeration and low mass activity and stability. Herein, a two-step synthesis approach is developed to create an L1 2 -Pt 3 Co intermetallic structure with an increased ordering degree and well-dispersed ultrafine particles. The first step of the synthesis yields ultrafine Pt nanoparticles that are well-dispersed on the ZIF-8-derived carbon support. The second adsorption step enables us to fine-tune the Pt and Co interfaces, assisted by optimal amino acids, to establish a favorable Co-rich environment around fine Pt nanoparticles, facilitating Co diffusion into the Pt crystalline under mild thermal conditions (<800 °C). In conclusion, this two-step ordered L1 2 -Pt 3 Co catalyst is systematically evaluated using membrane electrode assemblies under heavy-duty vehicle (HDV) conditions and demonstrated exceptional performance and durability, retaining 1.35 A cm -2 only a 7% loss in current density at 0.7 V after an extensive accelerated stress test of 150,000 voltage cycles.

30 DIRECT ENERGY CONVERSION↗
DOE OSTI2026

Detect the Unobservable: Abnormality Detection in mixed Autonomy for Lane Change Maneuver with Following Vehicles’ Trajectories Only

Highly Automated Vehicles (HAVs) and Advanced Driver-Assistance Systems (ADAS) are transforming modern transportation with enhanced mobility, safety, and efficiency. Despite their advantages, cybersecurity vulnerabilities in these systems can lead to abnormal behavior, posing significant risks to surrounding human-driven vehicles (HDVs) in mixed traffic environments. Here, this article addresses the challenge of detecting abnormal lateral movements of HAVs/ADAS vehicles using only trajectory profiles of following HDVs. Specifically, we propose a novel modeling approach that captures both normal and abnormal lateral behaviors through vehicle kinematics, integrated decision-making processes, vehicle control using symbolic regression for lane change vehicles. Additionally, we introduce an abnormality detection framework that relies on observable HDV data, even in occlusion scenarios. The framework evaluates the sensitivity of various car-following models to detect abnormal behaviors, providing insights into the interaction between HAVs/ADAS and HDVs in mixed autonomy systems.

Connected and Automated vehicles↗
DOE OSTI2025

Review—Meeting Fuel Cell Catalyst Requirements for Heavy-Duty Vehicle Applications

Catalyst requirements for proton exchange membrane (PEM) fuel cells differ by applications. Commercial heavy-duty vehicle (HDV) applications consume more H 2 fuel and demand higher durability than many others and the total cost of ownership (TCO) of the vehicle is largely related to the performance and durability of catalysts. This article is written to bridge the gap between the industrial requirements and academic activity for advanced cathode catalysts with an emphasis on durability. From a materials perspective, the underlying nature of the carbon support, Pt-alloy crystal structure, stability of the alloying element, cathode ionomer volume fraction, and catalyst-ionomer interface play a critical role in improving performance and durability. We provide our perspective on four major approaches, namely, mesoporous carbon supports, ordered PtCo intermetallic alloys, thrifting ionomer volume fraction, and shell-protection strategies that are currently being pursued. While each approach has its merits and demerits, their key developmental needs for future are highlighted.

Ramaswamy, Nagappan (ORCID:0000000234302758)↗