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All sourcesNASA NTRSDOE OSTI
DOE OSTI2019

Field-Aged Glass/Backsheet and Glass/Glass PV Modules: Encapsulant Degradation Comparison

Ethylene vinyl acetate (EVA) is the predominant encapsulant in crystalline-silicon photovoltaic (PV) modules; however, its degradation is a subject of major concern, which causes significant power loss under field conditions. This article presents a comparison of EVA degradation in field-aged PV modules with glass/backsheet (G/B) and glass/glass (G/G) architectures. Modulelevel characterization included UV fluorescence imaging and I-V measurements. Material analytical techniques, including colorimetry, differential scanning calorimetry, thermogravimetric analysis, Fourier transform infrared spectroscopy, and Raman spectroscopy, were performed to correlate the module performance parameters with EVA material properties. An intense EVA discoloration in G/G modules was observed, which was corroborated by higher module Isc and Pmax degradation rates compared with its counterpart G/B modules. Higher power degradation was accompanied by a significant increase in EVA crosslinking, vinyl acetate content, yellowness index, and presence of functional groups containing unsaturated moieties that are linked to degradation products of photothermal reaction, and a higher decrease in the degree of crystallinity. The absence of a polymeric backsheet in hermetically sealed G/G modules, which restricts photobleaching and enhances the entrapment of volatile acetic acid and other degradation by-products, plays a major role in causing higher EVA degradation in G/G modules. This article concludes that EVA might have been a good choice of an encapsulant for the G/B modules over the decades, but it may prove to be an inappropriate choice for the G/G modules because of potential degassing, corrosion, and/or discoloration issues. Ionomers or polyester-based encapsulants like polyolefins could be best suited for G/G modules as it appears to be a current trend in the industry.

14 SOLAR ENERGY↗
DOE OSTI2025

Time‐series multi‐omics analysis of micronutrient stress in Sorghum bicolor reveals iron and zinc crosstalk and regulatory network conservation

Micronutrient stress impacts growth, biomass production, and grain yield in crops. Multi-omics studies are valuable resources in identifying genes for functional studies and trait improvement, such as accumulation of Fe or Zn under deficient or excess conditions for bioenergy or grain agriculture. We conducted transcriptomics and ionomics analyses on Sorghum bicolor BTx623, grown under Fe and Zn limited and excess conditions over a 21-day period. To identify early and late transcriptional response in roots and leaves, 180 RNAseq libraries were sequenced for differential expression and co-expression network analyses. Fe and Zn accumulation was measured using ICP-MS at each time point, and a fluorometer was used to estimate chlorophyll content in leaves. Among the four treatments, Fe limitation and Zn excess resulted in the largest phenotypic effects and transcriptional response in roots and leaves. Several of the reduction (Strategy I) and chelation (Strategy II) strategy genes that improve bioavailability of Fe and Zn in plant roots often used by non-grass and grass species, respectively, were differentially expressed. Gene regulatory network (GRN) analysis of roots revealed enrichment of genes from Fe limiting and Zn excess which strongly connect to homologues of SbFIT, SbPYE, and SbBTS as hub genes. The GRN for leaf responses showed homologues of SbPYE and SbBTS as hubs connecting genes for chloroplast biosynthesis, Fe-S cluster assembly, photosynthesis, and ROS scavenging. Expression analyses suggest sorghum uses Strategy II genes for Fe and Zn uptake, as expected, but can also utilize Strategy I genes, which may be advantageous in variable moisture environments. We found strong overlap between Fe and Zn responsive GRNs, indicative of micronutrient crosstalk. We also found conservation of root and leaf GRNs, and known homologous genes suggest strong constraints on homeostasis networks in plants. These data will provide a resource for functional genetics to enhance micronutrient transport in sorghum, and opportunities to conduct further comparative GRN analysis across diverse crops species.

59 BASIC BIOLOGICAL SCIENCES↗
DOE OSTI2025

Thrifting iridium for hydrogen

Using renewable electricity to produce hydrogen fuel reduces reliance on fossil fuels. Proton exchange membrane water electrolyzers (PEMWEs) are the highest-performing commercialized technology. These devices split water into oxygen gas and hydrogen ions (protons) at the anode. The protons then migrate through an ion-conducting polymer membrane (ionomer) to be reduced to hydrogen gas at the cathode. Further, the anode reaction’s harsh environment requires the use of precious-metal catalysts, such as iridium oxide (IrO x ). Given the expense and scarcity, the design of electrodes that minimize the use of precious metals without compromising the requisite stability and activity is desired for large-scale hydrogen production. On page 791 of this issue, Shi et al. report that anchoring IrO x catalysts onto porous cerium-oxide (CeO x ) supports maintains performance even with much reduced precious metal use.

08 HYDROGEN↗
DOE OSTI2020

Pore-Filled PEMs from Poly(Phenylene Sulfonic Acid)s and Electrospun Poly(Phenylene Sulfone) Fiber Mats

A novel, composite, non-PFSA-based fuel cell membrane has been fabricated using a pore filling technique. The membrane consists of a mechanically stabilizing skeleton from an electrospun poly(phenylene sulfone) (PPSU) fiber mat and a thermally crosslinkable poly(phenylene sulfonic acid) (cPPSA) proton conducting ionomer that fills the interfiber voids. cPPSA copolymer was synthesized using Ullmann coupling copolymerization of 4,4-dibromobiphenyl 3,3-disulfonic acid with 1,4-dibromobenzene-2,5-disulfonic, followed by grafting a certain fraction of backbone sulfonic acid groups with biphenyl linker. The PPSU fiber mat was electrospun from NMP/acetone solution. Pore-filling was carried out by pouring a solution of cPPSA in methanol over the mat, followed by heating at 70°C to evaporate solvent. The cPPSA was crosslinked by an additional heating step, in a vacuum oven at 210°C for 5 hours. Here the resultant membrane had excellent proton conductivity, 5 times greater than that of Nafion® 211 in the 40-90% RH range at 80°C.

25 ENERGY STORAGE↗
DOE OSTI2021

Editors’ Choice—Diffusion Media for Cation Contaminant Transport Suppression into Fuel Cell Electrodes

Polymer electrolyte membrane fuel cells provide an alternative option to fossil fuel-based energy conversion devices. However, the corrosion of fuel cell components, specifically the bipolar plates, introduces contaminants (e.g., Fe, Ni) into the membrane electrode assembly (MEA). These contaminants accelerate the ionomer degradation by acting as a Fenton’s reagent, decreasing the fuel cell’s durability. This study presents the mechanism and the diffusion media properties affecting the transport of cation contaminants into the MEA. Cation contaminant transport was studied after altering the gas diffusion layers (GDLs) wettability, emulating the GDL properties after prolonged operation, by ex situ hydrogen peroxide treatment or in situ electrochemical potential cycling. A GDL with crack-free microporous layer (MPL) showed a lower cation transport rate to the catalyst layer than MPL with cracks after both ex situ and in situ treatment. A novel GDL was developed from modification of the conventional GDL via the addition of a hydrophobic layer to the GDL substrate, which suppressed the contaminant cation transport significantly. This novel GDL also showed improved fuel cell performance.

25 ENERGY STORAGE↗
DOE OSTI2021

Investigation of Membrane Chemical Degradation as a Function of Catalyst Platinum Loading

Membrane chemical degradation is one of many factors that can impact fuel cell durability. Additionally, the fuel cell’s lifetime heavily depends on the membrane and its ability to maintain chemical and mechanical integrity. Previous studies indicate that chemical degradation is due to the formation of hydroxyl radicals that attack the polymer structure resulting in membrane thinning, pinhole formation, and the release of fluoride and sulfate ions. Membrane durability was investigated using ultra-low Pt electrode loadings (≤ 0.1 mg Pt cm -2 ). Accelerated stress testing (US-DOE protocols) demonstrated that the degradation rate was found to increase with higher Pt loadings. This is most likely due to more heterogeneous sites for radical formation due to hydrogen crossover to the cathode. We also explored membrane degradation rates while varying catalyst layer thickness, ionomer to carbon ratio, and types of carbon support. All of the aforementioned variables impact the membrane degradation rates.

25 ENERGY STORAGE↗
DOE OSTI2022

Ion Chromatography and Combustion Ion Chromatography Analysis of Fuel Cell Effluent Water During Open Circuit Voltage

Open circuit voltage tests were conducted on sixteen 3M Ionomer and eight Nafion™ NR211 membranes. Lifetime distributions were determined, and ion chromatography (IC) techniques were used to measure fluoride, sulfate, trifluoro acetate, and oxalate ions. Combustion Ion Chromatography (CIC) was used to determine the total organic fluoride (TOF) associated with water soluble membrane degradation fragments. The ratio of these products relative to the fluoride release rates were used to infer the likely degradation mechanism for each membrane. Peroxide attack at the sulfonic acid side chain was determined to be the least relevant reaction pathway while the long-proposed polymer chain end unzipping appears to be the dominant mechanism. Abstraction of the tertiary fluorine in the NR211 backbone and side chain is evident by organic fluoride release rates higher than can be explained by unzipping alone.

25 ENERGY STORAGE↗
DOE OSTI2023

Anolyte Enhances Catalyst Utilization and Ion Transport Inside a CO 2 Electrolyzer Cathode

Electrochemical CO 2 reduction is a promising technology to capture and convert CO 2 to valuable chemicals. High Faradaic efficiencies of CO 2 reduction products are achieved with zero-gap alkaline CO 2 electrolyzers with a supporting electrolyte at the anode (anolyte). Herein, we investigate the effect of anolyte on the electrode properties such as catalyst utilization, ionic accessibility etc. of a CO 2 reduction cathode using electrochemical techniques and cell configurations that avoid the complexities related to co-electrolysis. Using 1M KOH as the anolyte and a Cu gas-diffusion-electrode with low Nafion content as the model CO 2 reduction electrode, we find that electrode capacitance (proxy for electrochemically active surface area) and ionic conductivity inside the cathode increase approximately 4 and 447 times, respectively, in presence of KOH. Liquid anolyte wets the electrode’s pore structure more efficiently than capillary condensation of feed water vapor. The ionomer coverage is very low, and its distribution inside the electrode is highly fragmented. Surface ion conduction mechanisms inside the electrode are orders of magnitude lower than the bulk ion conduction in presence of anolyte. This study shows that when an anolyte (e.g., KOH) is used, catalyst utilization and ionic accessibility inside the electrode increase significantly.

30 DIRECT ENERGY CONVERSION↗
DOE OSTI2023

Baselining Activity and Stability of ORR Catalysts and Electrodes for Proton Exchange Membrane Fuel Cells for Heavy-Duty Applications

Activity and stability of electrodes with Pt and PtCo alloy catalysts supported on high surface area carbon, hereafter to as a-Pt/C and d-PtCo/C, were evaluated for heavy-duty applications. Both catalysts had nearly identical Pt loading (50-wt% Pt on carbon and 0.25 mg Pt cm −2 ) and had undergone thermal treatment to stabilize them by growing the average particle size to 4–5 nm. Both were subjected to 90,000 (90 k) standard accelerated stress tests (AST) cycles consisting of 0.6–0.95 V square wave potentials, 3-s hold at upper and lower potential limits in H 2 /N 2 at 1.5 atm, 80 °C and 100% RH. Test protocols were developed to monitor the performance losses and characterize them in terms of activity for the oxygen reduction reaction (ORR), oxygen transport in the electrode and proton transport in the membrane and cathode catalyst layer. Despite the nearly double initial ORR activity, the PtCo/C electrode degraded faster due to the leaching of Co from the catalyst that had started even before the imposition of the AST potential cycles. Commensurate with Co leaching, Co poisoning of ionomer is responsible for the inferior performance of d-PtCo/C electrode at high current densities both before and after AST.

30 DIRECT ENERGY CONVERSION↗
DOE OSTI2023

Degradation Effects at the Porous Transport Layer/Catalyst Layer Interface in Polymer Electrolyte Membrane Water Electrolyzer

The porous transport layer (PTL)/catalyst layer (CL) interface plays a crucial role in the achievement of high performance and efficiency in polymer electrolyte membrane water electrolyzers (PEMWEs). This study investigated the effects of the PTL/CL interface on the degradation of membrane electrode assemblies (MEAs) during a 4000 h test, comparing the MEAs assembled with uncoated and Ir-coated Ti PTLs. Our results show that compared to an uncoated PTL/CL interface, an optimized interface formed when using a platinum group metal (PGM) coating, i.e., an iridium layer at the PTL/CL interface, and reduced the degradation of the MEA. The agglomeration and formation of voids and cracks could be found for both MEAs after the long-term test, but the incorporation of an Ir coating on the PTL did not affect the morphology change or oxidation of IrO x in the catalyst layer. In addition, our studies suggest that the ionomer loss and restructuring of the anodic MEA can also be reduced by Ir coating of the PTL/CL interface. Optimization of the PTL/CL interface improves the performance and durability of a PEMWE.

30 DIRECT ENERGY CONVERSION↗
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 OSTI2023

Do Melamine and Melamine-Formaldehyde Surface Modifiers Improve Fuel Cell Activity and Durability?

Precious group metal-based catalysts based on Pt- and Pt-alloys are currently used as catalysts for the kinetically sluggish Oxygen Reduction Reaction (ORR) on the cathode of fuel cells. The activity of Pt or Pt-alloy catalysts towards ORR is severely compromised by the adsorption of spectator-species such as sulfonate anions from perfluorosulfonic acid (PFSA) ionomer or Pt-O(H) ad via water activation. Considering recent evidence pointing to the improvement in ORR activity via the use of melamine organic molecule or melamine-formaldehyde copolymeric additives as surface blocking agents for the prevention of sulfonate or Pt-OH ad adsorption, we evaluated these additives in fuel cells. The catalysts were modified with either of these additives and characterized using ex situ and in situ methods to verify successful adsorption and eventual performance in fuel cells. These surface modifying agents were found to suppress Pt-OH ad formation as well as suppress ORR activity. There was no evidence to point out that these additives improved ORR activity and H 2 /air polarization performance in a fuel cell MEA on supported, polycrystalline Pt catalyst.

08 HYDROGEN↗
DOE OSTI2023

Electrochemical Measurement of Water Transport Numbers in Anion-Exchange Membranes

Anion-exchange membranes (AEMs) are a possible replacement for perfluorosulfonic-acid membranes in energy-conversion devices, primarily due to the hydroxide mobile ion allowing the devices to operate in alkaline conditions with less expensive electrocatalysts. However, the transport properties of AEMs remain understudied, especially electro-osmosis. In this work, an electrochemical technique, where the open-circuit voltage is measured between two ends of a membrane maintained at different relative humidities, is used to determine the water transport number of various ionomers, including Versogen and Sustainion AEMs and Nafion cation-exchange membrane (CEM), as a function of water content and temperature. In addition, the CEMs and AEMs are examined in differing single-ion forms, specifically proton and sodium (CEM) and hydroxide and carbonate (AEM). Carbonate-form AEMs have the highest transport number (∼11), followed by sodium-form CEMs (∼8), hydroxide-form AEMs (∼6), and proton-form CEMs (∼3). Finally, a multicomponent transport model based on the Stefan-Maxwell-Onsager framework of binary interactions is used to develop a link between water transport number and water-transport properties, extracting a range for the unmeasured membrane water permeability of Versogen as a function of water content.

30 DIRECT ENERGY CONVERSION↗
DOE OSTI2025

Membrane Thickness Impact on Chemical Degradation Rates

Abstract A comprehensive investigation of PFSA membrane chemical degradation rates as a function of thickness (8-20 µm) is reported. The two-pronged study was conducted on bare membranes and as components of chemically-mitigated and mechanically-reinforced, state-of-the-art (SOA) membrane electrode assemblies (MEAs). The bare membranes were subjected to H2O2 vapor test and MEAs were degraded under OCV conditions, both at 90°C. Both test types employed fluoride release rates (FRR) to monitor chemical degradation rates. Vapor tests revealed that area-specific degradation rates were positively correlated with membrane thickness, but thickness normalized degradation rates were independent of thickness. Open-circuit voltage (OCV) investigations spanning the membrane thickness series of MEAs was probed via a 27-experiment 3(4-1) fractional factorial experimental design. Statistical analysis of the FRR values revealed that chemical degradation rates were dominated by the relative humidity value and that the area-specific degradation rates of MEAs were independent of membrane thickness. The OCV chemical durability insensitivity to membrane thickness is supported by on-load membrane chemical durability studies at the stack level. The results suggest that ,despite smaller ionomer inventory, SOA thin membranes and MEAs are not greatly disadvantaged relative to thicker membranes from a chemical durability perspective, provided oxidative stress levels are controlled throughout application lifetime.

Coms, Frank D. (ORCID:0000000249160350)↗
DOE OSTI2026

Membrane Degradation in PEM Fuel Cells: Part I. Modeling Gas Crossover and the Pt Band

Understanding chemical degradation of the proton-exchange membrane in fuel cells is crucial for extending their lifetimes. Herein, various degradation reactions reported in literature are organized and analyzed, including direct radical generation and an indirect (Fenton) pathway. To understand the transport of dissolved H 2 and O 2 crossover gases as they relate to membrane degradation, an agglomerate-scale model is introduced, treating gas, ionomer, and catalyst as discrete phases. The model reveals a key phenomenon: at working potentials, dissolved gases are mostly consumed at the interface between the catalyst layer and the membrane, leaving little gas to cross the membrane. Under open-circuit conditions, dissolved gases are not consumed and can then cross the membrane. This explains high H 2 O 2 concentrations and degradation rates seen in experiments but not captured in previous models. Following mixed-potential theory, crossover gases supply the hydrogen-oxidation and oxygen-reduction reactions, which occur simultaneously on individual Pt particles comprising the Pt band in the membrane, forming reactive species (H 2 O 2 , OH·). Results show crossover gas almost entirely reacts on the Pt band, allowing little to reach the opposite electrode. Furthermore, the micro-scale geometry of the catalyst-layer/membrane interface impacts the gas crossover at working potentials, indicating that cell construction affects membrane durability.

Johnson, Evan F. [Lawrence Berkeley National Labor↗
DOE OSTI2023

Reports From The Frontier: Overcoming Limitations for Pure-water Anion-exchange-membrane Electrolysis

Anion-exchange-membrane electrolysis is positioned to play a key role in the predicted exponential growth of green hydrogen technology with essential R&D advances. We reveal key design parameters essential to commercialization. First, stable alkaline oxygen-evolution reaction catalysts with high electronic conductivity and minimal surface reconstruction during operation must be designed. Alkaline catalyst layers must also be applied to the membrane electrode assembly with scalable, industrially relevant techniques. Second, ionomer oxidation mitigation strategies must be developed. Furthermore, this approach could also target other creative catalyst layer design, such as phase-separation control to protect oxidation-prone organic components or catalyst engineering to direct selectivity for hydroxide over polymer oxidation. If competitive efficiency and durability can be achieved in pure water, AEM electrolysis has the potential to become a dominant electrolyzer technology.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2020

Influence of Proton Activity Gaps between Electrodes on Open-Circuit Potential of H 2 /H 2 and H 2 /Air Cells

Polymer -electrolyte-fuel-cell open-circuit voltages (OCVs) are exactly defined by equation (1), where cathode and anode proton activities [(aH+)cathode and (aH+)anode, respectively] usually are identical, so the third term in the right-hand side of equation (2) is ignored. OCV=E0+RT/2F*ln(a1/2 O2*(a2 H+)cathode/aH2O)-RT/2F*ln((a2 H+)anode/aH2) (1) =E0+RT/2F*ln(a1/2 O2*aH2/aH2O)+RT/2F*ln((a2 H+)cathode/(a2 H+)anode) (2) Water vapor pressure is a colligative property that fundamentally correlates to electrolyte concentrations in aqueous solutions. Proton activity is a function of acid concentration, such as pH, when electrolytes are acids. In polymer-electrolyte membranes, water vapor pressure and acid concentration are understood as relative humidity (RH) and water uptake (λ), respectively, where λ represents number of water molecules per sulfonic acid molecule. Several investigations have reported the relationship between RH and λ, meaning that proton activities and associated water uptakes are intimately related to RH. In actual fuel cell operation, cathode RH is determined by ambient-atmosphere and/or humidifier RH(s), and anode RH depends on hydrogen-circulator RH. Therefore, RH is not always identical at both electrodes, and the difference between electrode RHs is considerable during dry operation of polymer electrolyte fuel cells. Therefore, the third term in the right-hand side of equation (2) may be significant for dry operation. We measured OCVs when hydrogen was supplied to both electrodes at 80°C. One electrode (A) was fixed at 30% RH, while RH at the other electrode (B) was varied (0, 5, 10, 20, and 30%). Measured OCVs varied from 0 to 75 mV. For fuel cell tests, electrode A was supplied with hydrogen at 30% RH; electrode B, oxygen at 0, 5, 10, 20, and 30% RH. OCVs deviated from that measured when RH at electrode B was 30%, increasing from 0 to 60 mV with decreasing RH at electrode B. Results are also shown in Figure 1. Proton activities of both electrodes were thermodynamically calculated. The Gibbs–Duhem relation was applied to obtain molar Gibbs free energies of water and sulfonic acid, and proton activity coefficient was calculated using the Gibbs free energy of sulfonic acid and the relationship between RH and λ1–4, assuming that protons and sulfonic anions show identical ionic-activity coefficients. OCVs were estimated using the third term in the right-hand side of equation (2). Results are shown in Figure 1. Fuel-cell current–voltage performance was poor when RHs at the anode and cathode were 30 and 20%, respectively. To determine kinetic current, we measured the oxygen-reduction reaction (ORR) using a rotating-disk electrode (RDE) in concentrated-acid aqueous solutions, which modeled catalyst-layer ionomers. Kinetic currents decreased with acid concentrations. References T. A. Zawodzinski, Jr., C. Derouin, S. Radzinski, R. J. Sherman, V. T. Smith, T. E. Springer and S. Gottesfeld , J. Electrochem. Soc., 140,1041 (1993) P. K. Das and A. Z. Weber, Proceedings of the ASME 2013 11th Fuel Cell Science, Engineering and Technology Conference, Fuel Cell 18010 (2013) V. A. Sethuraman, J. W. Weidner, A. T. Haug, S. Motupally,b and L. V. Protsailo, J. Electrochem. Soc., 155, B50 (2008) A. Kusoglu and A. Z. Weber, Chem. Rev., 117, 987 (2017) Figure 1

Yoshida, Toshihiko↗