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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 37 records · Page 2
All sourcesNASA NTRSDOE OSTI
DOE OSTI2025

A Novel Three-Phase Isolated LLC and Non-Isolated LCL-T Resonant Converter for Fuel Cell Applications

In this paper, a novel three-phase isolated LLC and non-isolated LCL−T resonant converter topologies are introduced for fuel cell applications. In order to improve the fuel cell DC/DC converter efficiency, the current amplitude should be reduced in the power stage components. Cascaded connections of fuel cell blocks through a controllable system enable using higher voltage amplitude and bring the current amplitude lower at the target power. In this way, power losses in the passive components can be reduced, and maximum energy transfer can be established, improving the DC/DC converter efficiency from the fuel cell to the load. The introduced new converter also achieves soft switching (ZVS), minimizing the switching losses in all input and output load conditions. The presented three-phase isolated LLC and non-isolated LCL−T resonant converter systems, fed by three fuel cell modules with an output range of 190380 V, deliver 580−730 V at 450 kW maximum output power. The results reveal that the proposed systems have the advantage of reducing the size, volume, and weight and increasing the overall DC/DC converter system efficiency compared to the single-phase systems.

Asa, Erdem [ORNL] (ORCID:0000000190884812)↗
DOE OSTI2025

Heterostructured nano-catalysts with efficient metal-oxide interfaces unlock high-performance direct methanol protonic ceramic fuel cells

Direct methanol protonic ceramic fuel cells (PCFCs) are attractive due to their low cost, convenient storage, and high volumetric energy density, as well as their suitability for transportation. However, the poor coking tolerance of conventional nickel-based anodes leads to their susceptibility to severe carbon deposition and significant deactivation after long-term exposure to hydrocarbons. Herein, we report a nano-catalyst of Ce 0.6 Ni 0.2 Cu 0.2 O 2 with a heterogeneous structure that is spontaneously reduced into a Ce 0.6 Ni 0.2-x Cu 0.2-x O 2-δ (CeNCO) oxide framework interfaced with a nano NiCu alloy (denoted as NC/CeNCO) under operating conditions, as confirmed by analyses of X-ray diffraction, X-ray photoelectron spectroscopy, scanning electron microscopy, and transmission electron microscopy. A Ni-BaCe 0.7 Y 0.06 Yb 0.06 Zr 0.06 Hf 0.06 Gd 0.06 O 3-δ anode-supported PCFC employing the NC/CeNCO metal-oxide catalyst achieved a peak power density of 1.11 W cm −2 and operational stability of about 100 h at 700 °C when fueled by 35 % CH 3 OH-15 % H 2 O-50 % N 2 . In conclusion, the enhanced performance and coking resistance are attributed to the efficient interfaces of Ni, Cu, and ceria-based oxide in NC/CeNCO for CH 3 OH reforming, as confirmed by analyses of electrochemical performance and Raman spectroscopy with density functional theory calculations, revealing that these interfaces can enhance CH 3 OH activation and promote efficient OH-mediated carbon removal via COH intermediates.

30 DIRECT ENERGY CONVERSION↗
DOE OSTI2024

Machine learning-guided design of direct methanol fuel cells with a platinum group metal-free cathode

Direct methanol fuel cells (DMFCs) offer a promising solution for clean electricity generation, particularly in small electronics and remote auxiliary power units. However, optimizing their efficiency and performance is challenging due to the complex interactions between various factors. Here, we present a novel approach that integrates experiments with machine learning to model and predict the performance of these fuel cells using atomically dispersed platinum group metal (PGM)-free catalysts at the cathode. Further, our machine learning models, trained on diverse input parameters, allow for the comprehensive optimization of DMFC performance prior to fabrication and testing. Through extensive experimental validation, we demonstrate that this data-driven approach accurately predicts key performance metrics, such as maximum power output and polarization curves. By combining our models with interpretable game-theory methods, we provide deep insights into the factors governing fuel cell performance, ultimately paving the way for the design of scalable and efficient DMFC technologies.

25 ENERGY STORAGE↗
DOE OSTI2025

PFSA-Ionomer Adsorption to C and Pt/C Particles in Fuel-Cell Inks

Catalyst inks used to make fuel-cell electrodes consist of Pt/C catalyst particles and a perfluorosulfonic acid (PFSA) ionomer dispersed in water/alcohol solvent mixtures. PFSA ionomer in the ink adsorbs to the surface of the catalyst particles, dictating the dispersion colloid properties. Following adsorption, the subsequent distribution of excess nonadsorbed ionomer in the ink then governs the final structure of the electrode. Here, we characterize the adsorption of the PFSA ionomer onto Pt/C catalyst particles. PFSA adsorption is largely irreversible. Adsorbed sulfonic-acid moieties impart a negative charge on the catalyst surface, causing electrostatic repulsion between the free ionomer in solution and the ionomer-covered Pt/C particle surface. The amount of adsorption is limited by the resulting electrostatic charge that grows as more ionomer adsorbs, and the catalyst surface becomes more negatively charged. Attenuating electrostatic repulsion by increasing the ink ionic strength promotes ionomer adsorption. Electrostatically limited adsorption is observed, irrespective of the solvent water/n-propanol ratio or the catalyst particle porosity and Pt loading. Experimentally measured ionomer adsorption isotherms are well predicted by a Smoluchowski-based kinetic adsorption model, in which the electrostatic energy barrier for adsorption is predicted from DLVO theory. These findings help to unravel the complex phenomena within these colloidal dispersions, allowing for subsequent tailoring of inks to optimize fuel-cell electrode structure and performance.

Adsorption↗
DOE OSTI2026

Hybrid Fuel Cell Systems for Heavy-Duty Trucks: Configuration, Heat Rejection, and Performance

Low-temperature polymer electrolyte membrane fuel cell systems can achieve higher efficiency than diesel engines, but heat rejection remains a major challenge in class-8 heavy-duty fuel cell trucks. For the same rated power, the radiator heat load is greater than that in a diesel engine, while the allowable operating temperatures are lower. This work proposes and evaluates 400 kWe fuel cell–battery hybrid (FCH) platforms and operating strategies that manage heat rejection without enlarging the radiator frontal area. Three FCH platforms are identified, each varying in fuel cell system (FCS) rated power, battery energy storage system (ESS) capacity, and maximum stack coolant exit temperature (T h1 ). All three satisfy key system and vehicle requirements, including 175 kWe FCS power at top sustained speed, 400 kWe FCH power on a 6% grade climb, a target stack power density (PD) of 750 mW e /cm 2 , and heat rejection constraints. The first FCH has the smallest FCS, the largest ESS, and a T h1 of 90 °C. The second achieves the highest PD of 840 mW e /cm 2 at a T h1 of 95 °C. The third has the largest FCS, the smallest ESS, and a T h1 of 102 °C. At a Th1 of 115 °C, the platform can be configured as a stand-alone 400 kWe(net) FCS without hybridization, but the achievable PD drops to 460 mW e /cm 2 .

25 ENERGY STORAGE↗
DOE OSTI2025

Sulfonated Diels–Alder Poly(Phenylene)s in Membrane Electrode Assemblies for Fuel Cells

The transition to environmentally sustainable materials in fuel cells requires alternatives to persistent polyfluoroalkyl substances (PFAS) like Nafion. This study investigates the performance-limiting factors of membrane electrode assemblies (MEAs) utilizing sulfonated Diels–Alder poly(phenylene)s (sDAPPs) as PFAS-free polymer electrolytes. Among the configurations evaluated, the greatest performance loss occurred when sDAPP is used as the cathode binder, primarily due to phenyl group adsorption on catalyst surfaces, which reduces oxygen reduction reaction activity and impedes oxygen transport. Additional performance degradation arises from membrane-electrode interfacial incompatibility and insufficient ionomer hydrophobicity. By addressing ionomer adsorption and improving interfacial contact, an sDAPP-based cathode achieved a current density of 1.57 A cm −2 at 0.6 V under fully humidified H 2 /air conditions at 80 °C and 150 kPa abs . These results offer key insights for advancing high-performance, PFAS-free fuel cell technologies.

08 HYDROGEN↗
DOE OSTI2026

BIL High Speed Fuel Cell Stack Manufacturing

General Motors LLC (GM) was awarded a project to develop and implement technologies for manufacturing 20,000 units of Fuel Cell Stacks per year on two shifts per day basis. GM leveraged prior in-house expertise in designing the Fuel Cells, deploying the manufacturing process steps in the laboratory environment as well as the deployment in the industrial environment on a smaller scale. The project focus was to design, build, and deploy a manufacturing line consisting of an anode and cathode electrode processing, unitized electrode assembly, fuel cell stacking, compression, testing, and final assembly of the fuel cell stack. The project was terminated in the first budget period.

08 HYDROGEN↗
DOE OSTI2026

Cummins PEM Fuel Cell System for Heavy Duty Applications

The motivation for this project was to develop a high-pressure 100+ kW fuel cell stack that can be used in a modular fashion to power HD applications up to 1 MW. One of the issues that was identified during fuel cell system integration was the need for extra space for heat rejection systems(radiators) as well as additional fans and associated energy consumption to compensate for lower operating temperatures of fuel cells compared to internal combustion (IC) engines. To maximize the heat rejection capability of existing water-based coolant systems that are prevalent on IC engine-based systems, fuel cell stack design was developed to withstand and operate at IC engine coolant temperatures or higher, which in turn helps to reduce the radiator size requirement.

08 HYDROGEN↗
DOE OSTI2025

The search for high-entropy fuel-cell catalysts using disorder descriptors

The transition to a hydrogen economy depends on efficient, affordable catalysts for fuel cells. Platinum—the industry standard for fuel-cell electrodes—is costly and scarce, highlighting the need for practical alternatives. High-entropy alloys offer vast compositional diversity and tunable properties that can mitigate these issues, yet their chemical complexity and configurational disorder have hindered rational discovery. Here, we introduce a data-driven framework that couples machine learning with first-principles disorder descriptors—including the entropy forming ability, disordered enthalpy-entropy descriptor, and electronic-structure similarity metrics to platinum—to predict alloy synthesizability and catalytic performance. These descriptors are applied for the first time in the context of fuel-cell catalyst discovery. The workflow rapidly screens more than 20 000 compositions and identifies several platinum-free candidates that are economically viable, readily scalable, and exhibit promising predicted activity. These results demonstrate that disorder descriptors are reliably predicted by machine learning models and can be effectively integrated into materials-discovery pipelines, accelerating innovation across complex compositional spaces.

fuel-cell catalysts↗
DOE OSTI2026

Domestically Manufactured Fuel Cells for Heavy Duty Applications

This project, funded by the U.S. Department of Energy under Award DE-EE0009248, advances the domestic development of fuel-cell stack technologies for heavy-duty transportation applications. The work directly supports the Million-Mile Fuel Cell Truck (M2FCT) initiative by improving performance, durability, and manufacturability—key requirements for next-generation hydrogen fuel-cell systems.

08 HYDROGEN↗
DOE OSTI2024

Stabilizing alkaline fuel cells with a niobium-doped brookite titanium dioxide catalyst support

Anion-exchange membrane fuel cells represent a promising and scalable approach for hydrogen energy utilization. However, their development is hindered by the weak bonding between metal catalysts and carbon supports, along with challenges in fabricating electronically/ionically conductive electrodes. Here, we report a composite cathode of Nb-doped brookite TiO 2 nanorods that have robust stability when combined with Pt nanoscale catalysts in an alkaline fuel cell. The composite cathode, fabricated without the addition of an ionomer, delivers a power density of 419 mW cm −2 at a current density of 650 mA cm −2 and a voltage retention of 81% at 100 mA cm −2 after 25 h, substantially outperforming a cathode fabricated from commercial Pt/C. Further investigations of the chemical structure, anion exchange capacity, and mass transfer resistance reveal that a solvent residue derived from N-methylpyrrolidone plays an important role in charge transfer and mass transport in the alkaline fuel cell.

alkaline fuel cell↗
DOE OSTI2025

Forming Limits of Thin Ferritic Stainless Steel for Fuel Cell Application

To lower the cost of fuel cell bipolar plate (BPP), less expensive ferritic stainless steel (FSS) BPP substrate materials are investigated. A series of tensile tests and multistage microchannel-forming tests were conducted on 85-µm-thick ferritic stainless steel foils, 439L, 444, and Chromeshield® 22, to understand the effect of the forming temperatures, tooling geometry, and processes on their formability. Three microchannel-forming processes were conducted, which are 1-Hit (single-stage forming), 2-Hit (two-stage forming) with 50% preform, and 2-Hit with 80% preform. FLC o s at various microchannel-forming conditions were obtained to address the formability of the ferritic stainless steel foils under plane strain conditions. It has been found that the larger the microchannel radius, the better the formability, two-stage forming is superior to the single-stage process, and a larger draw percentage in preform (stage I) leads to a higher FLC o or better formability. It has also been found from tensile tests that the thermal effect (higher temperature) has a negative impact on the failure strains. A similar phenomenon was also observed through channel-forming tests conducted at room temperature, 100 °C, and 200 °C.

08 HYDROGEN↗
DOE OSTI2026

Translating Fundamental Insights into Ag-Based Bimetallic Electrocatalysts to Anion-Exchange Membrane Fuel Cells

To address challenges of high costs and scalability for fuel cells, it is essential to develop af-fordable and earth-abundant materials that are Pt-group-metal (PGM)-free. Recent advance-ments in PGM-free electrocatalysis for the oxygen reduction reaction (ORR) in alkaline media show that high catalyst loadings are needed to achieve high reaction rates; however, there are associated mass transport limitations. To address this issue, we develop low-loading ionomer-less Ag-bimetallic thin films by alloying with 3d block elements or Sn. We bridge knowledge from fundamental rotating disk electrode (RDE) studies to gas-diffusion cathodes in high-temperature anion-exchange membrane fuel cells (HT-AEMFCs), resulting in high-activity ORR catalysis and peak power densities up to 1.2 W cm-² geo for the Ag-Sn and Ag-Co alloys. Here, experimental post-characterization and theoretical calculations reveal small Co or Sn oxide nano-islands on Ag as likely active sites enhancing ORR activity, ultimately offering these low-loading PGM-free ORR materials as a viable path towards sustainable energy conversion.

Catalysts↗
DOE OSTI2025

Effect of Carbon Support Heat Treatment on the Performance of Ion-Pair High-Temperature PEM Fuel Cells

Heat treatment can significantly alter the physical and chemical properties of carbon supports, thereby influencing the performance of proton exchange membrane (PEM) fuel cells. This study explores how varying carbon heat treatment temperatures—from 1,000 °C to 2,200 °C—affect the structure and performance of platinum-based catalysts in high-temperature PEM fuel cells. Increasing the heat treatment temperature led to a notable decrease in surface area, along with increases in carbon grain size and hydrophobicity. Although the catalyst supported on carbon treated at 1,000 °C exhibited the highest catalyst activity, the MEA using carbon treated at 1,500 °C delivered the best overall fuel cell performance. This is attributed to an optimized balance between hydrophobicity and accessible surface area, which enhances water management and catalyst utilization. These findings underscore the importance of carbon support engineering in improving the efficiency of ion-pair high-temperature PEM fuel cells.

08 HYDROGEN↗
DOE OSTI2024

Inverse Consequences of the SnO 2 Protection Layers on Pt/C Catalysts in Proton-Exchange Membrane Fuel Cells

Proton-exchange membrane fuel cells (PEMFCs) are promising energy-conversion systems, offering an appealing blend of high energy efficiency and low environmental impact. However, carbon corrosion of PEMFCs is known to significantly degrade their performance, remaining a critical challenge to overcome. In this study, we applied a Nb-doped SnO 2 (Nb-SnO 2 ) nanoparticle coating on Pt/C catalysts as a protective layer, with the Sn/C ratio in the precursors varying from 0.25:1 to 2.0:1. Contradictory behaviors of the coated Pt/C catalysts were observed at different Sn/C ratios. The Sn/C = 1.0 sample exhibited improved electrochemically active surface area retention after 500 cycles of accelerated stress testing (AST) but with more significant polarization and resistance increase observed in the polarization curves. In addition, agglomeration of Nb-SnO 2 particles was observed at a higher Sn/C ratio in the AST of a membrane electrode assembly, with less shrinkage of the total thickness of the Nb-SnO 2 -coated Pt/C electrode. We speculate that formation of Nb-SnO 2 agglomerates occurs once the protective layer is broken down or the unprotected carbon surface is corroded and that these Nb-SnO 2 agglomerates increase the tortuosity of the electron pathways and significantly increase the cell polarization.

30 DIRECT ENERGY CONVERSION↗
DOE OSTI2026

System-Level Efficiency Study of Modular DC/DC and Fuel Cell Stack Series–Parallel Configurations

This paper presents a system-level efficiency study of modular DC/DC converter and fuel cell stack configurations under series, parallel, and series–parallel connections. The investigation considers selected DC/DC converter topologies, including isolated and non-isolated architectures, boost, non-inverting buck-boost, and resonant converters, integrated with commercially available fuel cell stacks, including the Accelera FCE150, Ballard FCgen-HPS, and Toyota TFCM2. DC/DC converter modules are evaluated in modular configurations rated at 60 kW and 90 kW and two distinct output voltage ranges, specifically 580–730V and 780–930V, examining how different interconnection schemes impact overall system efficiency. The converters are evaluated under full load (100%), partial load (66%), and light load (33%) conditions, providing a comprehensive assessment of efficiency and operational characteristics across varying power demands. Approximately two-thousand efficiency data points are obtained from laboratory prototype–level component measurements and validated design evaluations across multiple converter topologies, modular configurations, voltage ranges, and load conditions, providing a robust dataset for comparative system-level efficiency analysis. The results highlight the effects of modularity and topology selection on system-level efficiency, offering a “playbook” framework for designers to select appropriate DC/DC converter arrangements and fuel cell stack connections for series, parallel, or hybrid configurations based on efficiency considerations.

DC/DC↗
DOE OSTI2024

Power Electronics Manufacturing Improvements for Heavy-Duty Fuel Cell Vehicles

The Marel Power Solutions project, funded by the U.S. Department of Energy under Award DE-SC0023801, focused on advancing manufacturing techniques for power electronics in heavy-duty fuel cell vehicles. The research aimed to enhance system efficiency, reduce costs, and support broader adoption of hydrogen fuel cell technology. Key areas of investigation included power topology, thermal modeling, system architecture, and accessibility through software tools. Key Accomplishments: 1. Power Topology: - Developed an interleaved boost converter with optimized phase count, leveraging Marel’s proprietary Power Stacks. - Achieved reduced parasitic inductance and resistance, enabling high efficiency in DC-DC converters. 2. Thermal Modeling: - Integrated innovative cooling systems into compact Silicon Carbide (SiC) modules. - Simulations demonstrated the ability to dissipate significant heat (up to 7.5 kW), ensuring device reliability under heavy loads. 3. System Architecture: - Utilized simulation tools to analyze the impact of various fuel cell and vehicle parameters on efficiency. - Highlighted the role of smaller, modular improvements, such as enhanced DC-DC converters, in achieving system-wide gains. 4. Accessibility: - Evaluated and implemented MATLAB/Simulink code generation tools for real-world hardware applications. - Demonstrated the potential for rapid prototyping of custom power systems with reduced development costs. Impact and Benefits: - Efficiency and Cost Reduction: Marel’s cooling technology enhances SiC die performance, reducing the number of dies required and overall system size. - Scalability and Flexibility: The innovations support tailored solutions for diverse applications, from mass transit to mining vehicles. - Sustainability: The research promotes the integration of electrification technologies, helping meet rising energy demands sustainably. Conclusion: The project’s outcomes advance the state of power electronics for hydrogen fuel cell vehicles, enabling more efficient, compact, and cost-effective solutions. These developments lay a foundation for future innovation, contributing to the broader adoption of clean energy technologies in transportation and other industries.

08 HYDROGEN↗
DOE OSTI2025

Bridging interfacial properties and cell performance: A multiscale model for proton-exchange-membrane fuel cells

Here, to elucidate the impact of local interfaces on mass-transport resistance and overall cell performance of low-loaded proton-exchange-membrane fuel cells (PEMFCs), we present a multiscale modeling framework incorporating a novel modified agglomerate model. The model considers three distinct Pt-electrolyte interfaces: Pt on the carbon surface covered by either ionomer or water film and Pt inside carbon nanopores. Detailed mass-transport voltage-loss breakdowns reveal that coupled agglomerate-interface-scale mass transport dominates the mass-transport loss. The ionomer poisons the exterior-Pt surface through suppressing O 2 adsorption and intrinsic ORR activity, leading to low current-density performance. Conversely, interior-Pt interface enhances the kinetic performance but limits high current-density performance due to its low interfacial permeability. The exterior-Pt/water interface demonstrates superior kinetic performance and mass transport, though its practical implementation requires ensuring proton transport. By coupling the multiscale CL properties with ink parameters, the model identifies an optimal I to C ratio of approximately 0.5, a moderate value where the ionomer content is sufficient to guarantee proton transport without fully covering the Pt surface and forming large agglomeration, thus allowing the utilization of the Pt-water interface and avoiding high mass-transport loss. Overall, the model helps unravel limiting phenomena across different operating regimes and provides routes for optimizing performance.

Cell diagnostic↗