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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 325 records · Page 18
All sourcesNASA NTRSDOE OSTI
DOE OSTI2021

Carbon Corrosion in Polymer Electrolyte Fuel Cells: A Complex Interplay between Morphological Changes and Electrochemical Performance

Due to the high gravimetric energy density of hydrogen, the focus of implementation of polymer electrolyte fuel cells (PEFCs) has shifted from light duty passenger vehicles to heavy duty vehicles such as buses, trucks, locomotives and marine vessels. A mechanistic understanding of degradation is therefore necessary to improve durability and efficiency. During start-up and shut-down (SUSD) of PEFC systems, the catalyst (Pt nanoparticles embedded on carbon support) undergoes local potentials ~ 1 - 1.5 V caused by a combination of fuel (H 2 ) starvation, mixed fuel region and cell reversal. This leads to a series of degradation phenomenon including reduction in cathode catalyst layer (cCL) thickness and porosity, loss in electrochemical surface area (ECSA), ionomer degradation and loss in electrical contact, therefore resulting in severe performance loss. The convoluted relationship between these individual degradation mechanisms, their chronology and their effects on electrochemical performance are yet unresolved. Here, the complex interplay between morphological changes due to carbon corrosion and its effects on the electrochemical performance were analyzed using a combination of detailed electrochemical characterization, spectroscopy, and electron microscopy techniques.

25 ENERGY STORAGE↗
NASA NTRSDate not supplied

Development of Electrolytic Oxygen Recovery System for Advanced Life Support

The oxygen (O2) recovery system for the International Space Station (ISS) can recover approximately 50 percent of O2 from metabolic carbon dioxide (CO2). Increasing the O2 recovery rate and closing the open loop for future long duration crewed missions in space beyond Low Earth Orbit (LEO) is essential. There are several developmental efforts underway to increase the recovery rate. However, most of these technologies result in a complex, heavy, and power consuming system. The desired exploration O2 recovery system would be reliable and efficient with maximum O2 recovery. Marshall Space Flight Center (MSFC) is currently investigating an electrolytic O2 recovery approach that will increase the O2 recovery to greater than 70 percent as well as lowering the complexity, mass, and power consumption than most other technologies currently under development. The electrolytic O2 recovery system consists of a Microfluidic Electrochemical Reactor (MFECR) that is based on the electrochemical reduction of CO2 to O2 and ethylene (C2H4) using water (H2O) as precursor and operates at standard condition with a theoretical recovery rate of 73 percent. In 2016, NASA’s Game Changing Development Program awarded the University of Texas Arlington (UTA) a grant to initiate the development of the MFECR. Since 2019, MSFC and UTA have been collaborating with the current goals of increasing the O2 recovery efficiency, advancing the technology readiness to a Technology Readiness Level (TRL) 4, and maturing the system to process CO2 of one crew-member. Based on the results from UTA’s initial efforts, the following were identified as key areas of improvement in order to maximize O2 recovery for the system: further development of the anode material and cathode catalyst, model-based cell design optimization, and the addition of a separation system and fuel cell. This paper will present the current developmental efforts of the electrolytic system including MFECR design and overall system enhancements as well as results from single cell stack testing.

Brittany R Brown↗
DOE OSTI2020

Tailoring electrode microstructure via ink content to enable improved rated power performance for platinum cobalt/high surface area carbon based polymer electrolyte fuel cells

Improvements in polymer electrolyte fuel cell (PEFC) electrode performance have primarily focused on catalyst and ionomer developments, marginalizing the importance of catalyst ink formulation. In this study, the effect of ink formulation is examined across a series of cathodes comprised of PtCo supported on high surface area carbon (PtCo/ HSC ) and Nafion ionomer using an array of in situ electrochemical and ex situ characterization techniques. In contrast to prior work on Pt/Vu systems, ink water content had little effect on the electrochemically determined ionomer coverage for the PtCo/HSC electrocatalyst examined here. Characterization using nano-scale resolution X-ray computed tomography (nano-CT) demonstrated that water-rich ink formulations lead to a reduction in aggregate size (ionomer + PtCo/HSC), improving local O 2 transport. This understanding, combined with the use of a commercially-available electrocatalyst was used to produced state-of-the-art membrane electrode assemblies with Pt loadings of 0.03/0.08 mg Pt /cm 2 on the anode and cathode respectively, having; i) > 1 A/mg Pt (0.9 V iR-free , 150 kPa, 80 °C, 100% RH, H 2 /O 2 ), ii) 320 mA/cm 2 at 0.8 V, 150 kPa, 80 ° C, 100% RH, H 2 /Air), and iii) > 1 W/cm 2 elec at rated power (0.67 V, 250 kPa, 94 °C, 65% RH, H 2 /Air) or < 0.11 g Pt /kW rated .

25 ENERGY STORAGE↗
DOE OSTI2021

High-Current Density Durability of Pt/C and PtCo/C Catalysts at Similar Particle Sizes in PEMFCs

The durability of carbon supported PtCo-alloy based nanoparticle catalysts play a key role in the longevity of proton-exchange membrane fuel cells (PEMFC) in electric vehicle applications. To improve its durability, it is important to understand and mitigate the various factors that cause PtCo-based cathode catalyst layers (CCL) to lose performance over time. These factors include i) electrochemical surface area (ECSA) loss, ii) specific activity loss, iii) H + /O 2 -transport changes and iv) Co 2+ contamination effects. We use a catalyst-specific accelerated stress test (AST) voltage cycling protocol to compare the durability of Pt and PtCo catalysts at similar average nanoparticle size and distribution. Our studies indicate that while Pt and PtCo nanoparticle catalysts suffer from similar magnitudes of electrochemical surface area (ECSA) losses, PtCo catalyst shows a significantly larger cell voltage loss at high current densities upon durability testing. The distinctive factor causing the large cell voltage loss of PtCo catalyst appears to be the secondary effects of the leached Co 2+ cations that contaminate the electrode ionomer. A 1D performance model has been used to quantify the cell voltage losses arising from various factors causing degradation of the membrane electrode assembly (MEA).

08 HYDROGEN↗
DOE OSTI2025

Mechanistic Insights into Oxygen Reduction Reaction on Metal Cathode Over BaZrO 3 -Based Electrolyte under Moist Atmosphere: Interfacial Interactions and Reaction Pathways

The oxygen reduction reaction (ORR) is a critical process that often governs the overall performance of electrochemical systems such as proton conducting solid oxide fuel cells. Despite its significance, the current understanding about the ORR, especially when it involves H 2 O is still limited. In this study, the proton involved ORR (PI-ORR) on metal cathode (e.g., Pt) over BaZrO 3 (BZO) electrolyte is investigated using density functional theory (DFT) under moist atmosphere. Two scenarios are considered: one at relatively high temperature (900 K) in the presence of oxygen vacancy in BZO substrate and one at relatively low temperature (700 K) without oxygen vacancy. We systematically explored oxygen vacancy effects on adsorption sites and proton transfer pathways, calculated energy profiles and Gibbs free energies for elementary steps along the O 2 dissociated and the O 2 concerted reaction pathways. We also evaluated H 2 O impacts on intermediate oxygen species (*O and *OH) through Ab Initio molecular dynamics. These analyses revealed pathway-dependent reaction mechanisms and hydration effects at triple-phase boundary, advancing fundamental understanding of PI-ORR in metal cathode/Ba-based electrolyte systems for energy applications.

08 - HYDROGEN↗
DOE OSTI2023

Unraveling the core of fuel cell performance: engineering the ionomer/catalyst interface

The biggest obstacle to the widespread implementation of polymer electrolyte membrane fuel cells (PEMFCs) is their cost, primarily due to the use of platinum catalysts. The high intrinsic catalyst activity exhibited on a rotating disk electrode (RDE) is rarely realized in a membrane electrode assembly (MEA), which is a long-standing challenge for PEMFCs and a cause of low catalyst utilization. To translate the high RDE performance of a catalyst into a MEA, the design of an ideal ionomer/catalyst interface is proposed: a thin, conformal ionomer film covers the maximum surface of a Pt nanoparticle and thus simultaneously maximizes catalyst utilization, (i.e., high mass activity and electrochemically active surface area) and O 2 diffusion rate (i.e., high current density performance) without compromising proton conduction. Building such an interface is a long-standing challenge due to the lack of interaction between the ionomer and catalyst particles, resulting in large ionomer agglomerates and inhomogeneous ionomer coverage over the catalyst nanoparticle, with consequent poor fuel cell performance. In this work, this ionomer/catalyst interface has been engineered, utilizing the electrostatic attraction between positively charged catalyst and negatively charged ionomer particles in a catalyst ink and preserved in a solid catalyst layer. As a result, this interface leads to previously unachieved proton exchange membrane fuel cell performance in terms of both catalyst utilization (75% vs. 45%) and peak/rated power density (i.e., 1.430/0.930 W cm -2 , H 2 /air, cathode Pt loading: 0.1 mgPt cm -2 ) for pure Pt catalysts, even better than those of Pt alloy catalysts. This work demonstrates the formation of an interface in the liquid phase (using ultra-small-angle X-ray scattering in combination with cryo-TEM, isothermal–titration–calorimetry) and the preservation of the interface in the solid catalyst layer (using TEM) and estimates the effective coverage and thickness of the ionomer film (using limiting current density, RDE and fuel cell performance).

25 ENERGY STORAGE↗
NASA NTRS2014

Method for Making a Fuel Cell from a Solid Oxide Monolithic Framework

The invention is a novel solid oxide fuel cell (SOFC) stack comprising individual bi-electrode supported fuel cells in which a thin electrolyte is supported between electrodes of essentially equal thickness. Individual cell units are made from graded pore ceramic tape that has been created by the freeze cast method followed by freeze drying. Each piece of graded pore tape later becomes a graded pore electrode scaffold that subsequent to sintering, is made into either an anode or a cathode by means of appropriate solution and thermal treatment means. Each cell unit is assembled by depositing of a thin coating of ion conducting ceramic material upon the side of each of two pieces of tape surface having the smallest pore openings, and then mating the coated surfaces to create an unsintered electrode scaffold pair sandwiching an electrolyte layer. The opposing major outer exposed surfaces of each cell unit is given a thin coating of electrically conductive ceramic, and multiple cell units are stacked, or built up by stacking of individual cell layers, to create an unsintered fuel cell stack. Ceramic or glass edge seals are installed to create flow channels for fuel and air. The cell stack with edge sealants is then sintered into a ceramic monolithic framework. Said solution and thermal treatments means convert the electrode scaffolds into anodes and cathodes. The thin layers of electrically conductive ceramic become the interconnects in the assembled stack.

Cable, Thomas L.↗
DOE OSTI2026

Adsorption-Engineered Hydrocarbon Ionomers for Durable Proton-Exchange Membrane Fuel Cells

Reducing reliance on perfluoroalkyl substances (PFAS) in proton-exchange membrane fuel cells requires hydrocarbon ionomers that combine high performance with long-term durability, a persistent challenge in catalyst-layer design. Here, we identify oxidation-driven ionomer-catalyst interfacial degradation as a dominant failure pathway in hydrocarbon ionomer-bonded cathodes and introduce an adsorption-engineering strategy to overcome this limitation. The comparison of a commercial sulfonated poly(phenylene) (Pemion) with structurally engineered sulfonated poly(fluorene)s demonstrated that electrode durability is governed by the interplay between ionomer adsorption strength and resistance to oxidative degradation on carbon-supported Pt catalysts. A poly(fluorene) ionomer with mobile alkyl sulfonic acid groups forms resilient interfaces, delivering 1.28 A cm−2 at 0.65 V under fully humidified H2/air conditions (80°C and 150 kPaabs), comparable to Pemion. After 90,000 accelerated potential cycles, the poly(fluorene)-bonded cathode exhibits significantly improved durability, with only 29% performance loss compared to 58% for Pemion; further molecular refinement reduces the loss to 17%, approaching that of Nafion-bonded cathodes (14%). These findings establish adsorption-engineered ionomer design that decouples interfacial anchoring from oxidative degradation as a general strategy for achieving durable, high-performance PFAS-free PEM fuel cell electrodes.

08 HYDROGEN↗
DOE OSTI2022

New Approaches to Improved PEM Fuel Cell Catalyst Layers

Polymer-electrolyte membrane (PEM) fuel-cells are one of the most promising energy conversion technologies for renewable clean energy applications. A major challenge preventing the widespread use and commercialization of PEM fuel cells is achieving high performance with low-loadings of platinum group metal (PGM) catalysts. One of the factors driving performance limitations in the cell is the mass transport losses within the cathode catalyst layers (CCL) due to sluggish oxygen-reduction reactions occurring at the platinum-ionomer interface. Any resistance to transport of these ionic and gaseous species within the CCL results in mass-transport limitations and performance losses, especially at high current densities. It is known that mass-transport losses increase with reduced platinum loading, thereby creating a performance-cost tradeoff for fuel cells. A viable solution to reduce the transport resistances in the catalyst layers is to create new ionomers that can provide good ion and oxygen transport needed to accomplish high-performing fuel cell catalysts. Using this approach Tetramer Technologies and LBNL propose improved fuel-cell catalyst ionomers based on Tetramers proprietary polymer chemistry.

30 DIRECT ENERGY CONVERSION↗
DOE OSTI2022

Review—Development of Highly Active and Stable Catalyst Supports and Platinum–Free Catalysts for PEM Fuel Cell

Metal-free, metal-containing, and template-assisted metal-containing nitrogen-modified carbon-based catalysts carbon composite supports, and highly active and electrochemically stable hybrid cathode catalysts for oxygen reduction reaction are reviewed in this manuscript. Here, novel procedures are developed for the synthesis of (i) highly catalytically active PGM-free catalyst and stable carbon composite catalyst supports. The carbon composite catalyst supports are engineered with optimized BET surface area and pore size distribution and with a well-defined kinetic and mass transfer region during the reaction and their performance is dicussed in detail in this review. The surface activation results in increasing carbon graphitization and inclusion of non-metallic active sites on the support surface. The USC catalysts exhibit the initial performance of 0.91 V and a maximum power density of 177 mW cm –2 , with well-defined kinetic and mass-transfer regions and ~2.5% H 2 O 2 production. Activated carbon composite support (ACCS) is modified to optimize its kinetic activity and its electrochemical stability shows excellent thermal stability and support stability under simulated start-up/shut-down operating conditions. The stabilities of various supports developed in this study are compared with those of a commercial Pt/C catalyst. The active sites for the ORR identified with electrochemical and physicochemical methods are pyridinic-N and quaternary-N.

25 ENERGY STORAGE↗
NASA NTRS1981

Preparation and evaluation of advanced electrocatalysts for phosphoric acid fuel cells

A number of electrocatalyst combinations were prepared and characterized. These electrocatalysts were formulated to contain platinum combined with transition metal carbide forming elements (W, Mo, V) for cathodes and platinum combined with palladium for anodes. High resolution electron microscopy was used to determine the crystallite size and dispersion of platinum-palladium alloy electrocatalysts in order to provide analytical support for the electrochemical determinations of the particle dispersions. An equation was derived which correlates palladium crystallite size with electrochemical hydrogen adsorption. Based on comparisons of electrocatalyst performances in the presence of pure hydrogen and hydrogen containing carbon monoxide, it was shown that the apparent poisoning of the electrocatalyst by carbon monoxide is influenced by the electrode structure.

Stonehart, P.↗
DOE OSTI2020

An all-oxide electrolysis cells for syngas production with tunable H 2 /CO yield via co-electrolysis of H 2 O and CO 2

High-rate production of syngas with tunable H 2 /CO and coke-free operation is achieved in a solid-oxide electrolysis cell (SOEC). Prior to operation, controlled pre-reduction of La 0.7 Sr 0.3 Fe 0.9 Ni 0.1 O 3-δ (LSFNi) cathode is used to trigger the in-situ exsolution of Ni-Fe alloy nanoparticles with an average size of ~45 nm uniformly distributed and socketed on LSFNi backbone, enabling efficient co-electrolysis of H 2 O and CO 2 to H 2 and CO. At 1.5 V, the current density reaches ~1.0 A cm-2 at 750 °C and ~2.4 A cm -2 at 850 °C with near 100% Faradaic Efficiency. We demonstrate the feasibility of tuning the output H 2 /CO ratio by nearly two orders of magnitude (from ~0.1 to ~7) by manipulating H 2 O/CO 2 ratio of feed gas, operating temperature, and current density. Finally, stable operation for >100 h is obtained without evidence of carbon deposition, although high current density operation leads to observable deterioration of anode/electrolyte interface due to the rapid oxygen evolution.

25 ENERGY STORAGE↗
DOE OSTI2022

Low-Pressure Electrolytic Ammonia (LPEA) Production

The project goal was to advance and demonstrate the techno-economic viability of a low-pressure electrolytic ammonia (LPEA) process for producing ammonia from electricity, hydrogen, and nitrogen. The critical enabling technology of the LPEA process is a proton-conducting electrolyte (PCE) developed by EERC and North Dakota State University (NDSU) capable of high proton conductivity (at least 1×10 -2 [0.01] siemens/centimeter [S/cm]) at 200°–300°C. An affordable PCE that works at 200°–300°C has been a major goal of the global electrochemistry industry for over 25 years, because it would enable operation at temperatures high enough to prevent catalyst poisoning and simplify water management and low enough to avoid temperature-driven degradation of fuel cell components comprising materials with differing coefficients of thermal expansion. Also critical to LPEA performance is a cathode catalyst capable of ammonia synthesis at a rate of ≥1×10 -10 moles/second-cm 2 catalyst surface area (mol-s -1 cm -2 ) in screening tests conducted at room temperature, and 1×10 -7 mol-s -1 cm -2 at 200°–300°C for commercial viability.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
NASA NTRS1989

A survey of advanced battery systems for space applications

The results of a survey on advanced secondary battery systems for space applications are presented. The objectives were: to identify advanced battery systems capable of meeting the requirements of various types of space missions, with significant advantages over currently available batteries, to obtain an accurate estimate of the anticipated improvements of these advanced systems, and to obtain a consensus for the selection of systems most likely to yield the desired improvements. Few advanced systems are likely to exceed a specific energy of 150 Wh/kg and meet the additional requirements of safety and reliability within the next 15 years. The few that have this potential are: (1) regenerative fuel cells, both alkaline and solid polymer electrolyte (SPE) types for large power systems; (2) lithium-intercalatable cathodes, particularly the metal ozides intercalatable cathodes (MnO2 or CoO2), with applications limited to small spacecrafts requiring limited cycle life and low power levels; (3) lithium molten salt systems (e.g., LiAl-FeS2); and (4) Na/beta Alumina/Sulfur or metal chlorides cells. Likely technological advances that would enhance the performance of all the above systems are also identified, in particular: improved bifunctional oxygen electrodes; improved manufacturing technology for thin film lithium electrodes in combination with polymeric electrolytes; improved seals for the lithium molten salt cells; and improved ceramics for sodium/solid electrolyte cells.

Attia, Alan I.↗
DOE OSTI2021

Tailoring catalyst layer structures for anion exchange membrane fuel cells by controlling the size of ionomer aggreates in dispersion

The development of anion exchange membranes and ionomers plays a critical role in performance of anion exchange membrane fuel cells. However, the optimal design of catalyst layer structures still remains unexplored despite its significance. Herein, the rational design guide is presented for cathode and anode catalyst layers using m-TPN1 ionomer by controlling the size of ionomer aggregates in dispersion and comparing various catalyst layer structures. The size of m-TPN1 aggregates decreases, creating a more uniform ionomer distribution and a larger triple-phase-boundary. As ionomer distribution of the cathode catalyst layer becomes more uniform, the power density of membrane-electrode-assembly is enhanced. Also, the power density at fully humidified condition strongly correlates with the porosity of anode catalyst layer due to the limitation of hydrogen transport at anode by water flooding.

42 ENGINEERING↗
DOE OSTI2022

Surface Regulating of a Double–Perovskite Electrode for Protonic Ceramic Fuel Cells to Enhance Oxygen Reduction Activity and Contaminants Poisoning Tolerance

Protonic ceramic fuel cells (PCFCs) are one of the most efficient energy conversion devices. However, the performance of current PCFCs is greatly limited by the sluggish oxygen reduction reaction (ORR) kinetics and the fast degradation of cathode due to contaminants poisoning (such as Cr species and steam). In this work, we report a surface regulating of a double perovskite PrBa 0.5 Sr 0.5 Co 1.5 Fe 0.5 O 5+δ (PBSCF) cathode by a Pr 0.9 Fe 0.7 Co 0.3 O 3 (PFC) catalyst coating to enhance the ORR activity and stability. When tested in direct contact with Cr in the air with 3% H 2 O at 650 °C, the polarization resistance (Rp) of the PFC-PBSCF electrode increases from $\approx$0.39 to 0.45 Ω cm 2 after 100 h operation; in contrast, the R p of a PBSCF electrode increases from 0.63 to 0.82 Ω cm 2 . Further, a PCFC with the PFC-PBSCF cathode demonstrates an excellent peak power density ($\approx$1.08 W cm -2 at 650 °C) and significantly enhanced durability (degradation rate of 0.03 % h -1 ), much better than those of the cells with a PBSCF cathode ($\approx$0.75 W cm -2 and degradation rate of 0.12 % h -1 ). Raman spectroscopy and density functional theory calculations indicate that the PFC catalyst coating diminishes the formation of Cr species, such as (Ba 1-x Sr x )CrO 4 , on the cathode surface.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗