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DOE OSTI2023

Engineered Catalyst Support with Improved Durability at Higher Weight Percentage of Platinum

Proton Exchange Membrane (PEM) fuel cells are a suitable electrochemical power source for heavy duty vehicle (HDV) applications due to their high efficiency and durability. The cathode of the fuel cell uses a higher geometric loading of platinum (∼0.2 to 0.4 mg Pt /cm 2 ) for the electrocatalysis of the kinetically sluggish Oxygen Reduction Reaction (ORR) which requires higher weight percent loading of the metal (∼50%) on the carbon support to decrease the catalyst layer thickness and hence, the reactant transport losses. The conventionally used supports for platinum catalyst, such as the KetjenBlack TM type high surface area carbon (HSC) features limited mesopore area for the dispersion of Pt nanoparticles leading to increased aggregation and poor durability. Here, we show a new class of carbon materials known as the Engineered Catalyst Support (ECS) developed by Pajarito Powder with higher mesopore fraction for the dispersion of higher weight percentage of Pt nanoparticles. ECS materials can disperse up to 50% Pt by weight of the catalyst thereby enabling lower catalyst layer thickness with higher performance retained after durability test. A comprehensive set of physico-chemical and electrochemical studies in membrane electrode assembly (MEA) are reported to understand the performance and durability of Pt/ECS catalysts.

08 HYDROGEN↗

DOE OSTI2024

Durability testing of actual Hanford waste glasses and their non-radioactive simulant glasses

The low-activity waste (LAW) fraction of Hanford tank waste will be converted to glass at the Waste Treatment and Immobilization Plant (WTP) and disposed on the Hanford site. The chemical durability of LAW glasses has been researched for decades to satisfy contract requirements. Most LAW glass durability data has been generated on non-radioactive simulant glasses fabricated via crucible melts. These non-radioactive glasses were chosen due to safety and cost reasons with confidence that radioactive waste glasses would exhibit similar behavior. To reduce the risk of significant differences in laboratory test response data between WTP melter waste glass and simulant glass, Product Consistency Tests (PCT, i.e., ASTM C1285-21) and Environmental Protection Agency (EPA) 1313 durability tests were performed on actual and simulant LAW glasses fabricated using laboratory-scaled melters. Actual and simulant glass durability test results are presented and statistically compared. Finally, differences in test responses were found to be within experimental uncertainty.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

DOE OSTI2022

Durability Evaluation of Advanced Fenestration Technologies

In the U.S., more than 40% of primary energy and 70% of electricity is consumed in residential and commercial buildings, resulting in annual energy costs of more than $430 billion. Approximately 35% of this consumption can be attributed to losses through the building envelope, of which windows are currently the weakest link. Multiple technologies are under development to improve this performance. This includes dynamic and photovoltaic glazing as well as emerging highly insulating technologies including vacuum insulating glass (VIG), aerogels and thin-glass based multi-pane configurations. While windows are specified based on expected performance as installed, the energy savings realized by high performance windows are delivered over time. This makes it critical to understand and maximize the durability of high-performance windows to ensure those projected energy savings are delivered. Present methods for evaluating durability are based on existing technologies. These methods may not apply or be adequate for newer emerging technologies which often present novel failure mechanisms that need to be understood and evaluated differently. In this presentation, we will discuss our efforts to define appropriate methods to improve the evaluation of many existing technologies as well as evaluate the durability of emerging window technologies. This work results from the combination of an extensive review of various international standards as well as existing scientific literature. In addition, input was gathered from multiple industry stakeholders regarding present practice as well as feedback on proposed improvements to existing methods. Here we will share these findings and present proposed improvements to developing and existing durability evaluation protocols.

building envelope↗

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 OSTI2023

Pathways Toward Efficient and Durable Anion Exchange Membrane Water Electrolyzers Enabled By Electro‐Active Porous Transport Layers

Abstract Green hydrogen, produced via water electrolysis using renewable electricity, will play a crucial role in decarbonizing industrial and heavy‐duty transportation sectors. Anion exchange membrane water electrolyzers (AEMWEs) can overcome many of the performance and cost limitations of incumbent technologies, however, still suffer from durability challenges due to oxidative instability of anion‐exchange ionomers. Herein, the use of an electro‐active porous transport layer as anode (PTL‐electrode) is demonstrated to enable efficient and durable AEMWEs. The stainless‐steel PTL‐electrodes are shown to have superior performance and durability compared to traditional catalyst layers containing ionomer and nanoparticle catalysts. An AEMWE cell operating at 2 A cm −2 for over 600 h exhibited a degradation rate of just 5 µV h −1 . During operation, the surface composition of the stainless steel transforms into a mixture of iron and nickel oxyhydroxides, contributing to enhanced oxygen‐evolution reaction activity. The combination of experimental work and modeling elucidates how the bulk structure of the PTL‐electrode offers an additional design dimension to further improve electrolyzer performance. Lastly, a surface modification strategy is applied to a PTL‐electrode to achieve an even higher performing AEMWE (2.3 vs 2.0 A cm −2 at 1.8 V). Overall, this work lays out pathways toward more efficient, durable, and affordable AEMWEs.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2025

Enhancing durability and activity toward oxygen evolution reaction using single-site Re-doped NiFeO x catalysts at ampere-level

NiFeO x materials are known as among the most active catalysts toward oxygen evolution reaction (OER) for hydrogen generation in alkaline media. Nevertheless, the long-term durability of NiFeO x catalysts for OER is still too far to the industrial application. Herein, we prepared a NiFeReO x catalyst with single-site Re dopants and observed that the single-site Re dopants could significantly enhance the durability without compromising the activity. A cell voltage of 1.82 V without iR correction is noted at the current density of 3000 mA cm –2 in anion-exchange membrane water electrolyzer (AEMWE) with NiFeReO x catalyst, and a very small degradation is observed under 2000 and 1000 mA cm –2 , which remarkably outperforms the pristine NiFeO x . Additionally, the overpotential of 305 mV at 10 mA cm –2 is achieved with the NiFeReO x catalyst, which is lower than 50 mV compared with the pristine NiFeO x catalyst, together with a smaller Tafel slope of 54.3 mV dec -1 . The boosted OER durability and activity of the NiFeReO x catalyst could be attributed to the strong electron-withdrawing property of Re 7+ single atoms leading to the electronic structure optimization and stabilization of Ni/Fe active sites. Our insights propose a new path for designing NiFeO x catalysts with high durability and activity toward OER.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2021

Machine learning-enabled prediction of chemical durability of A 2 B 2 O 7 pyrochlore and fluorite

Pyrochlore-structure type and its derivative in a general formula A 2 B 2 O 7 (A = rare earth elements and actinides; B = Ti, Sn, Zr, Hf, Pb, Si, etc.) display excellent structural flexibility and rich crystal chemistry as promising nuclear waste form materials capable of immobilizing actinides and fission products. It is essential to understand these materials’ chemical durability and element release of radionuclides in order to evaluate their performance in near-field environment. However, it is a formidable grand technological challenge to experimentally perform durability testing across hundreds of thousands of possibilities resulting from their extreme compositional complexities due to cation substitutions at both A and B-sites. In this work, we demonstrate a machine learning approach to determine the key materials parameters and structural characteristics governing the leaching behaviors from a small set of selected compositions as model systems, enabling a science-based prediction of their chemical durability that can be extended to a wide range of chemical compositions. The combination of four key structural characteristics and materials parameters, including ionic radius size difference , ionic potential difference , electronegativity difference , and lattice parameter , creates features an optimized prediction of the chemical durability. Two machine learning models, linear regression and Kernel ridge regression models, are trained on the randomly-split training dataset derived from the experimentally-determined elemental release rates, and subsequently tested on the testing dataset. The predicted leaching rates from both machine learning models show an excellent agreement with the experimental data, demonstrating the feasibility of rapidly evaluating the material properties of new compositions. These results highlight the immense potential of synergizing informatics through machine learning-based models and well-controlled experiments of selected model systems to accelerate materials design and discovery with optimized compositions and performance of promising materials for effective nuclear waste management.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

DOE OSTI2023

Pt Nanoparticles on Atomic-Metal-Rich Carbon for Heavy-Duty Fuel Cell Catalysts: Durability Enhancement and Degradation Behavior in Membrane Electrode Assemblies

Proton exchange membrane fuel cells (PEMFCs) are a promising zero-emission power source for heavy-duty vehicles (HDVs). However, long-term durability of up to 25,000 h is challenging because current carbon support, catalyst, membrane, and ionomer developed for traditional light-duty vehicles cannot meet the stringent requirement. Therefore, understanding catalyst degradation mechanisms under the HDV condition is crucial for rationally designing highly active and durable platinum group metal (PGM) catalysts for high-performance membrane electrode assemblies (MEAs). Herein, we report a PGM catalyst consisting of platinum nanoparticles with a high content (40 wt %) on atomic-metal-site (e.g., MnN 4 )-rich carbon support. MEAs with the Pt (40 wt %)/Mn–N–C cathode catalyst achieved significantly enhanced performance and durability, generating 1.41 A cm –2 at 0.7 V under HDV conditions (0.25 mgPt cm –2 and 250 kPa abs pressure) and retaining 1.20 A cm –2 after an extended and accelerated stress test up to 150,000 voltage cycles. Electron microscopy studies indicate that most fine Pt nanoparticles are retained on or/and in the carbon support covered with the ionomer throughout the catalyst layer at the end of life. During the long-term stability test, the observed electrochemical active surface area reduction and performance loss primarily result from Pt depletion in the catalyst layer due to Pt dissolution and redeposition at the interface of the cathode and membrane. Importantly, the first-principle density functional theory calculations further reveal a support entrapment effect of the Mn–N–C, in which the MnN 4 site can specifically adsorb the Pt atom and further retard the Pt dissolution and migration, therefore enhancing long-term MEA durability.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2021

Selecting durable building envelope systems with machine learning assisted hygrothermal simulations database

Hygrothermal simulations provide insight into the energy performance and moisture durability of building envelope components under dynamic conditions. The inputs required for hygrothermal simulations are extensive, and carrying out simulations and analyses requires expert knowledge. An expert system, the Building Science Advisor (BSA), has been developed to predict the performance and select the energy-efficient and durable building envelope systems for different climates. The BSA consists of decision rules based on expert opinions and thousands of parametric simulation results for selected wall systems. The number of potential wall systems results in millions, too many to simulate all of them. We present how machine learning can help predict durability data, such as mold growth, while minimizing the number of simulations needed to run. The simulation results are used for training and validation of machine learning tools for predicting wall durability. We tested Artificial Neural Network (ANN) and Gradient Boosted Decision Trees (GBDT) for their applicability and model accuracy. Models developed with both methods showed adequate prediction performance (root mean square error of 0.195 and 0.209, respectively). Finally, we introduce how the information supports guidance for envelope design via an easy-to-use web-based tool that does not require the end-user to run hygrothermal simulations.

Salonvaara, Mikael↗

DOE OSTI2021

Effect of Catalyst and Catalyst Layer Composition on Catalyst Support Durability

Polymer electrolyte membrane fuel cells (PEMFCs) are efficient, zero-emission engines for the automotive sector. However, cost and durability are major barriers for the commercialization of PEMFCs. Degradation of the carbon support in the cathode catalyst layer due to high potential excursions caused by unmitigated events like H 2 starvation, or start-up/shutdown are still a major durability issue in PEMFCs. Catalyst support durability was studied by accelerated stress tests (ASTs) that included repeated potential cycling from 1.0 to 1.5 V. The effect of catalyst layer composition on carbon corrosion was studied using membrane electrode assemblies with different catalysts (Pt, PtCo), catalyst composition (catalyst wt.%, supports), ionomer composition (loading, and equivalent weights). The corrosion of the carbon support is similar between Pt and PtCo catalysts. However, the performance degradation rate is higher for the alloy catalysts due to differences in catalyst particle size and the transition metal’s leaching accelerating the performance degradation. The carbon loss is lower for catalysts with lower initial carbon loading (or higher catalyst wt.%), which is better for durability. However, the cumulative loss of carbon is identical for electrodes with the same catalyst support irrespective of catalyst and ionomer composition in the catalyst layer.

25 ENERGY STORAGE↗

DOE OSTI2025

The Impact of Membrane Inactive Area on the Durability of Pt-Co Catalyst

Platinum (Pt) is the most active catalyst for oxygen reduction reaction; however, its activity still requires a significant increase to meet the demands of practical applications. To enhance the catalytic activity, alloy catalysts like platinum-cobalt (Pt-Co), are being extensively investigated. However, Co leaching from the Pt-Co alloy remains a significant concern. Evaluating the durability of Pt-Co alloy catalyst is further complicated by variations in Co leaching, which affects both the observed performance and durability. This variability often arises from an overlooked factor: choice of the inactive area of the membrane electrode assembly (MEA) used during the evaluation. This study examines the critical role of membrane inactive area on the performance loss observed during durability testing of Pt-Co alloys. Our findings indicate that a large membrane inactive area reduces the impact of Co leaching on performance and durability, up to 200 mA cm −2 difference in performance is observed between large and small inactive area MEA at 0.7 V for dry conditions, and more Co is retained in the active area of MEA for smaller inactive areas which is responsible for larger performance losses.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2023

(Invited) Fuel Cell Component Durability for Million Mile Fuel Cell Trucks

While significant advances have been made and early commercial fuel cell light-duty vehicles (LDVs) are starting to be produced, fuel cells in the heavy-duty-vehicle (HDV) transportation sector (including trucks, long-haul semitrailers, maritime, trains, etc.) are nascent, despite the fact that advantages of fuel cells compared to both diesel and electric powertrains are very compelling in terms of emissions, charging time, efficiency, power-to-weight ratio, among others. However, the fuel-cell technology for HDVs requires a paradigm shift in fuel-cell research and development compared to LDVs, where the emphasis becomes efficiency and improvements in durability instead of a focus on increased power densities and lower cell costs. Heavy-duty applications require significantly longer vehicle lifetimes (>25,000 hours/1,000,000 miles for heavy-duty trucks), and therefore require improved fuel cell durability compared to light-duty vehicles. In 2020, HFTO formed the Million Mile Fuel Cell Truck Consortium (M2FCT) that includes a core team of five national laboratories to overcome durability and efficiency challenges in PEMFCs for heavy-duty applications with an initial focus on long-haul trucks. While targets and testing protocols have been developed for light-duty vehicles, the same level of targets and testing protocols have not been established for heavy-duty transportation. With operational times of greater than > 25,000 hours required, the need for well-developed accelerated stress tests (ASTs) is amplified. Results from these ASTs demonstrate the need for more durable electrode layers and well-controlled potential variations. Finally, this presentation will provide an overview of the DOE's Fuel Cell R&D approach, highlighting past and current activities, as well as strategies to enable fuel cell competiveness for heavy-duty applications.

25 ENERGY STORAGE↗

NASA NTRS1986

Mechanical properties for durability predictions of FRP bonded joint

A discussion of current standard durability prediction methodology for bonded joints is given. The influence of time-dependent adhesive properties on lap shear stress distributions and interfacial stresses is presented. It is suggested that these effects may be important in durability considerations. Test geometries from which better durability information can be obtained are outlined and a general mechanics approach for durability prediction is suggested.

Brinson, H. F.↗

NASA NTRS1991

Relative sliding durability of two candidate high temperature oxide fiber seal materials

A test program to determine the relative sliding durability of two candidate ceramic fibers for high temperature sliding seal applications is described. Pin on disk tests were used to evaluate potential seal materials. Friction during the tests and fiber wear, indicated by the extent of fibers broken in a test bundle or yarn, was measured at the end of a test. In general, friction and wear increase with test temperature. This may be due to a reduction in fiber strength, a change in the surface chemistry at the fiber/counterface interface due to oxidation, adsorption and/or desorption of surface species and, to a lesser extent, an increase in counterface surface roughness due to oxidation at elevated temperatures. The relative fiber durability correlates with tensile strength indicating that tensile data, which is more readily available than sliding durability data, may be useful in predicting fiber wear behavior under various conditions. A simple model developed using dimensional analysis shows that the fiber durability is related to a dimensionless parameter which represents the ratio of the fiber strength to the fiber stresses imposed by sliding.

Dellacorte, Christopher↗

NASA NTRS1992

Relative sliding durability of two candidate high temperature oxide fiber seal materials

Dellacorte, Christopher↗

NASA NTRS1995

Materials research for high-speed civil transport and generic hypersonics: Composites durability

This report covers a portion of an ongoing investigation of the durability of composites for the High Speed Civil Transport (HSCT) program. Candidate HSCT composites need to possess the high-temperature capability required for supersonic flight. This program was designed to initiate the design, analysis, fabrication, and testing of equipment intended for use in validating the long-term durability of materials for the HSCT. This equipment includes thermally actuated compression and tension fixtures, hydraulic-actuated reversible load fixtures, and thermal chambers. This equipment can be used for the durability evaluation of both composite and adhesive materials. Thermally actuated fixtures are recommended for fatigue cycling when long-term thermomechanical fatigue (TMF) data are required on coupon-sized tension or compression specimens. Long term durability testing plans for polymer matrix composite specimens are included.

Allen-Lilly, Heather↗

NASA NTRS1996

Atomic Oxygen Durability Testing of an International Space Station Solar Array Validation Coupon

An International Space Station solar array validation coupon was exposed in a directed atomic oxygen beam for space environment durability testing at the NASA Lewis Research Center. Exposure to atomic oxygen and intermittent tensioning of the solar array were conducted to verify the solar array#s durability to low Earth orbital atomic oxygen and to the docking threat of plume loading both of which are anticipated over its expected mission life of fifteen years. The validation coupon was mounted on a specially designed rotisserie. The rotisserie mounting enabled the solar and anti-solar facing side of the array to be exposed to directed atomic oxygen in a sweeping arrival process replicating space exposure. The rotisserie mounting also enabled tensioning, in order to examine the durability of the array and its hinge to simulated plume loads. Flash testing to verify electrical performance of the solar array was performed with a solar simulator before and after the exposure to atomic oxygen and tensile loading. Results of the flash testing indicated little or no degradation in the solar array#s performance. Photographs were also taken of the array before and after the durability testing and are included along with comparisons and discussions in this report. The amount of atomic oxygen damage appeared minor with the exception of a very few isolated defects. There were also no indications that the simulated plume loadings had weakened or damaged the array, even though there was some erosion of Kapton due to atomic oxygen attack. Based on the results of this testing, it is apparent that the International Space Station#s solar arrays should survive the low Earth orbital atomic oxygen environment and docking threats which are anticipated over its expected mission life.

Forkapa, Mark J.↗

NASA NTRS2003

Advanced Durability and Damage Tolerance Design and Analysis Methods for Composite Structures: Lessons Learned from NASA Technology Development Programs

Aerospace vehicles are designed to be durable and damage tolerant. Durability is largely an economic life-cycle design consideration whereas damage tolerance directly addresses the structural airworthiness (safety) of the vehicle. However, both durability and damage tolerance design methodologies must address the deleterious effects of changes in material properties and the initiation and growth of microstructural damage that may occur during the service lifetime of the vehicle. Durability and damage tolerance design and certification requirements are addressed for commercial transport aircraft and NASA manned spacecraft systems. The state-of-the-art in advanced design and analysis methods is illustrated by discussing the results of several recently completed NASA technology development programs. These programs include the NASA Advanced Subsonic Technology Program demonstrating technologies for large transport aircraft and the X-33 hypersonic test vehicle demonstrating technologies for a single-stage-to-orbit space launch vehicle.

Harris, Charles E.↗