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At least 1,729 records · Page 96

Advances in Solid State Joining of Haynes 230 High Temperature Alloy

The J-2X engine is being designed for NASA s new class of crew and launch vehicles, the Ares I and Ares V. The J-2X is a LOX/Hydrogen upper stage engine with 294,000 lbs of thrust and a minimum Isp of 448 seconds. As part of the design criteria to meet the performance requirements a large film-cooled nozzle extension is being designed to further expand the hot gases and increases the specific impulse. The nozzle extension is designed using Haynes 230, a nickel-chromium-tungsten-molybdenum superalloy. The alloy was selected for its high strength at elevated temperatures and resistance to hydrogen embrittlement. The nozzle extension is manufactured from Haynes 230 plate spun-forged to form the contour and chemically-milled pockets for weight reduction. Currently fusion welding is being evaluated for joining the panels which are then mechanically etched and thinned to required dimensions for the nozzle extension blank. This blank is then spun formed into the parabolic geometry required for the nozzle. After forming the nozzle extension, weight reduction pockets are chemically milled into the nozzle. Fusion welding of Haynes results in columnar grains which are prone to hot cracking during forming processes. This restricts the ability to use spin forging to produce the nozzle contour. Solid state joining processes are being pursued as an alternative process to produce a structure more amenable to spin forming. Solid state processes have been shown to produce a refined grain structure within the joint regions as illustrated in Figure 1. Solid state joining processes include friction stir welding (FSW) and a patented modification termed thermal stir welding (TSW). The configuration of TSWing utilizes an induction coil to preheat the material minimizing the burden on the weld tool extending its life. This provides the ability to precisely select and control the temperature. The work presented in this presentation investigates the feasibility of joining the Haynes 230 alloy using the solid state welding processes of FSW and TSW. Process descriptions and attributes of each weld process will be presented. Weld process set-up and welding techniques will be discussed leading to the challenges experienced in joining the superalloy. Mechanical property data will also be presented.

Ding, R. Jeffrey↗

(abstract) Mars Pathfinder Active Thermal Control System: Ground and Flight Performance of a Mechanically Pumped Cooling Loop

A key element of the Mars Pathfinder thermal control system is the Heat Rejection System (HRS). The HRS of Mars Pathfinder is designed to actively control the temperatures of the various parts of the spacecraft.This is achieved by mechanically circulating single-phase Freon 11 liquid through the lander and cruise electronics box heat exchangers and transferring the heat to an external radiator on the cruise stage. This is the first time in spacecraft history that a mechanically pumped cooling loop has been used on a long duration spacecraft mission. Many lessons have been learned during the testing and ground and flight operation of the HRS. This paper will present the performance of the mechanically pumped cooling loop during the ground and flight operations. Based on the lessons learned from this experience, recommendations on the design and operation of the pumped cooling loops for future space missions will be made.

Mars↗

Performance Testing of a Lightweight, High Efficiency 95 K Cryocooler

Performance data are presented for a flight-like, lightweight, high efficiency pulse tube cryogenic cooler. The cooler has a mass of less than 4.0 kg, and an efficiency of 12 W/W, which is 18% of Carnot at 95 K, nearly double the efficiency of previous cooler designs, The mass of the cooler has been reduced by approximately a factor of three. The design point cooling power is 10 watts at 95 K at a heat rejection temperature of 300 K. The no-load temperature is 45 K. The compressor is built by Hymatic Engineering, UK, and is of a horizontally opposed piston design using flexure bearings. The vertical pulse tube is built by TRW with the heat exchanger or cold block located approximately mid-way along the tube. The final assembly and integration is also performed by TRW. The inertance tube and dead volume are contained within one of the compressor end caps. The cooler was developed by TRW under a joint NASA-DOD program, and has a goal of 10 yr operating lifetime. Potential NASA applications will focus on using coolers of this type in Zero boil off (ZBO) cryogen storage topologies for next generation launch vehicles. Zero boil off systems will feature significant reductions in tank size and Initial Mass to Low Earth Orbit (IMLEO), thereby significantly reducing the cost of access to space, and enabling future missions. The coolers can be used directly in liquid oxygen (LOx) or liquid methane ZBO systems, as shield coolers in liquid hydrogen tanks, or as first stage coolers in two-stage liquid hydrogen (LH2) ZBO cooler systems. Finally, the coolers could find applications in exploration missions where either propellants or breathable oxygen are extracted from the planetary atmosphere using a Sabatier or similar process. The gases could then be liquefied for storage either directly in return vehicle propellant tanks or on the planetary surface. Data presented were taken with the cooler operating in a vacuum of 10 (exp -5) torr, at controlled rejection temperatures from 300 K down to 275 K using a cold water heat exchanger bolted to the cooler. Heat loads were varied between 0.5 W and 15 W by supplying current to a 50 omega resistor mounted on a copper cold plate which was bolted to the cooler cold block. Silicon diodes mounted on both the cold plate and the heat exchanger provided accurate temperature measurement to within plus or minus 0.25 K and plus or minus 0.5 K respectively, up to 100 K with plus or minus 1% accuracy above 100 K. Input power to the compressor was limited to 180 W, corresponding to a maximum stroke of 80%.

Salerno, Lou↗

Thermal Model of the AGR-5/6/7 Experiment

Several fuel and material irradiation experiments have been planned for the U.S. Department of Energy Advanced Gas Reactor Fuel Development and Qualification Program, which supports the development and qualification of tristructural isotropic (TRISO) coated particle fuel for use in high-temperature gas-cooled reactors. The goals of these experiments are to provide irradiation performance data to support fuel process development, qualify fuel for normal operating conditions, support development of fuel performance models and codes, and provide irradiated fuel and materials for post-irradiation examination and safety testing. Originally planned and named as separate fuel experiments, but subsequently combined into a single test train, AGR-5/6/7 will test low-enriched uranium oxycarbide (UCO – a heterogeneous mixture of uranium oxide and uranium carbide) TRISO fuel. The AGR-5/6 portion of the experiment will provide data to support qualification of the selected reference fuel design, while the AGR-7 portion will serve as a margin test, irradiating the fuel beyond normal operating conditions. A thermal finite element model has been created for the five capsules comprising the AGR-5/6/7 experiment. Heat rates from a physics analysis are imported into the model along with fast neutron fluence. Graphite shrinkage due to the fast neutron fluence is incorporated into the model. Gas gaps change as a function of fast neutron fluence. Radiation heat transfer is a major contributor in this model. This is a large model with more than 1 million finite element brick elements. More than 150 different parts are modeled in the finite element model and communicate with each other from a heat transfer sense. More than 50 thermocouples are used in the experiment and are compared to actual measurements. The experiment is composed of five separate stainless steel capsules all welded together. Each capsule has its own Helium/.Neon gas mixture to help control the temperature of the capsule.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

Leveraging slow $\mathrm{DOTA}$ f-element complexation kinetics to enable separations by kinetic design

The design of metal-concerned solvent extraction systems frequently leverages thermodynamically derived differences in selectivity. An alternative approach, leveraging kinetic control, has been considered much less seriously. Our recent manuscript describing DOTA (1,4,7,10-tetraazacyclododecane-1,4,7,10-tetraacetic acid) complexation kinetics across the lanthanide series shows the observed rate constant steadily increases across the series, with some non-monotonic behavior observed at terbium and thulium. This contrasts the thermodynamic stability constant trend, where lanthanide-DOTA stability constants initially increase and then plateau as a function of ionic radii after samarium. To leverage the kinetic differences of DOTA with the lanthanides across the series, kinetically based separations must be utilized. Since DOTA has very slow complexation kinetics, a separations system must expedite DOTA-metal complexation to allow a separation approximating practical application. Here in this report, a DOTA-based solvent extraction system, where DOTA is the aqueous holdback reagent and bis-2,4,4-trimethylpentylphosphinic acid (Cyanex 272) is the organic phase extractant, is demonstrated and compares the separations chemistry of Nd, Eu and Am. The slowness of DOTA complexation was addressed by heating the system. Results showed, in general, separation between metals is better during early phase contact, and diminishes under longer contact times. Under all conditions, separations are better than would be predicted based on a thermodynamic basis. This report suggests that while slowly complexing ligands classically used for biological applications may not be appropriate for thermodynamically designed metal separations, their use for kinetically based systems may be appropriate and enable a new design basis for f-element separations.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

Fundamental Studies of Metal Centered Transformations Relevant to Catalysis

The overall objectives the research performed have been to advance the mission of the U. S. Department of Energy, with specific emphasis concerned with the conversion and use of fossil and renewable energy resources, and the synthesis of advanced chemicals. Achieving this objective requires improvements in rational catalyst design by establishing details of reaction mechanisms and their kinetics. Therefore, over the course of this award, emphasis has been directed towards obtaining detailed information concerned with fundamental transformations that occur at metal centers, with particular attention given towards reactions such as (i) hydrodesulfurization (HDS) and hydrodenitrogenation (HDN), (ii) the use of carbon dioxide as a renewable C1 feedstock, (iii) the generation of hydrogen on demand, and (iv) transformations that involve the cleavage of H–H, C–H and C–C bonds. HDS and HDN are the essential processes for removing sulfur- and nitrogen-containing impurities from crude oil in order to obtain (i) cleaner fuels that minimize environmental pollution and (ii) cleaner chemical feedstocks that are less likely to poison the catalysts that are used for subsequent transformations. The catalysts employed for HDS and HDN are typically molybdenum and tungsten sulfides and, to gain insight into these transformations at the molecular level, we have focused on developing the coordination chemistry of heterocyclic sulfur and nitrogen compounds with molybdenum and tungsten. For example, we obtained the first examples of the cleavage of thiophene C–S bonds by employing molecular molybdenum compounds. The efficient utilization of carbon dioxide as a renewable C 1 source for the synthesis of value added organic chemicals and fuels has prompted much effort towards developing catalytic reactions to functionalize CO 2 . One such approach is hydrosilylation, which can proceed in a stepwise manner to afford a series of products with different levels of reduction, namely silyl formates, silyl acetals, methoxy silanes and methane. Despite the utility of these transformations, however, most catalysts employ precious metals, which operate at elevated temperatures, and control of the level of reduction is challenging. Therefore, it is significant that we have developed zinc and magnesium systems that can achieve hydrosilylation of CO 2 and which may be modified to control the level of reduction. The growing demand for energy requires the development of alternative energy sources that are more sustainable than fossil fuels and have a reduced impact on the environment. In this regard, an attractive energy storage medium is provided by hydrogen, which can, for example, be consumed in a fuel cell with only water as a byproduct. Unfortunately, a problem with using hydrogen in this manner is that present storage and transportation techniques are inadequate. For example, not only does storing liquid hydrogen present a safety risk, considerable energy is also required to liquefy the hydrogen and maintain it in this form. Therefore, we have focused on the application of chemical methods to provide hydrogen on demand. One such method utilizes formic acid as a storage medium and we reported the first examples of molybdenum compounds that serve as catalysts for releasing H 2 from formic acid. The nature of the interaction of a C–H bond with a metal center is of pivotal importance in many transformations of organic molecules, and we have examined several systems to probe how the interaction varies according to whether the metal is molybdenum or tungsten. These studies demonstrate that tungsten exhibits a greater propensity to cleave a C–H bond. While the oxidative addition of C–H bonds to a metal center is well precedented, transformations that feature oxidative addition of C–C bonds are uncommon and so it is noteworthy that we have observed the cleavage of a strong C–C bond that is a component of an unstrained 6-membered aromatic ring. The oxidative addition of dihydrogen to a metal center, and its microscopic reverse, reductive elimination, are two of the simplest yet most important transformations in organometallic chemistry. For example, oxidative addition of dihydrogen is a key step in many transition metal-catalyzed reactions involving H 2 . However, relatively few studies have established in detail the factors that influence the thermodynamics of this transformation. Therefore, it is significant that we demonstrated experimentally that that the energetics of the oxidative addition of H 2 to the six coordinate molybdenum and tungsten halide complexes depends very strongly on the nature of both the metal and the halogen. Deuterium kinetic isotope effects (KIEs) and equilibrium isotope effects (EIEs) serve as versatile tools to infer details about reaction mechanisms. In this regard, primary deuterium isotope effects are often interpreted by using two simple guidelines: (i) the KIE for an elementary reaction is normal (k H /k D > 1) and (ii) the EIE is dictated by deuterium preferring to be located in the site corresponding to the highest frequency oscillator. We have evaluated the applicability of these rules to the interactions of H–H and C–H bonds with a transition metal center and our results question the ability to predict primary EIEs in these systems based on the simple notion that deuterium prefers to occupy the highest frequency oscillator. The key findings are that the EIEs for (i) formation of σ–complexes by coordination of H–H and C–H bonds and (ii) oxidative addition of dihydrogen exhibit unusual temperature dependencies, such that the same system may exhibit both normal (i.e. K H /K D > 1) and inverse (i.e. K H /K D < 1) values.

02 PETROLEUM↗

In Situ Study on Fracture Behavior of Thick-Section Friction Stir-Welded AA 5083 Alloy

Friction stir welding (FSW) produces a gradient microstructure with distinct metallurgical zones. Here, the present study focuses on characterizing the fracture behavior during uniaxial loading across thick-section FSW joint in nonheat-treatable 5083 aluminum alloy. The hardness variation is linked to microstructural features across the weld zones through correlative microscopy. Notably, the heat-affected zone (HAZ) exhibits a lower hardness of 75 HV, while the thermomechanically affected zone (TMAZ) and stir zones (SZ) display a hardness of around 79HV. A marginal difference in hardness in HAZ prompts strain localization in HAZ on the advancing side of the weld, resulting in offset in fracture from the SZ, which is captured through in situ monitoring of the tensile test. Further, the postdeformation analysis reveals crack propagation along the maximum shear stress plane due to the coalescence of microvoids resulting from the fracturing and debonding of second-phase particles. Overall, this study provides valuable insight for optimizing the FSW process of AA 5083 alloy for thick-section applications.

36 MATERIALS SCIENCE↗

Thermochromic Halide Perovskite Windows with Ideal Transition Temperatures

Abstract Urban centers across the globe are responsible for a significant fraction of energy consumption and CO 2 emission. As urban centers continue to grow, the popularity of glass as cladding material in urban buildings is an alarming trend. Dynamic windows reduce heating and cooling loads in buildings by passive heating in cold seasons and mitigating solar heat gain in hot seasons. Here, reduced energy consumption in highly glazed buildings in a mesoscopic building energy model is demonstrated when thermochromic windows are employed. Savings are realized across eight disparate climate zones of the United States. The model is used to determine ideal critical transition temperatures of 20–27.5 °C for thermochromic windows based on metal halide perovskite materials. Ideal transition temperatures are realized experimentally in composite metal halide perovskite films composed of perovskite crystals and an adjacent reservoir phase. The transition temperature is controlled by cointercalating methanol, instead of water, with methylammonium iodide and tailoring the hydrogen‐bonding chemistry of the reservoir phase. Thermochromic windows based on metal halide perovskites represent a clear opportunity to mitigate the effects of energy‐hungry buildings.

14 SOLAR ENERGY↗

ReaxFF reactive force field model enables accurate prediction of physiochemical and mechanical properties of crystalline and amorphous shape‐memory polyurethane

Abstract We investigate reactive force field (ReaxFF) prediction of physiochemical and mechanical properties, and stimuli response behavior of a shape‐memory polyurethane (SMPU) rigid segment. We used SMPUs as a platform to link the rigid/hard segment domain crystallinity with properties that can also be experimentally measured. Specifically, we developed models for crystalline and amorphous forms of a common rigid segment of SMPUs, for example, 4,4′‐diphenylmethane diisocyanate (MDI) with n‐butanediol (BDO), denoted as MDI‐BDO. ReaxFF molecular dynamics simulations with equilibrium dynamics are performed by controlling mass, temperature, and pressure or volume to predict the structural and physiochemical properties of crystalline and amorphous rigid segments of SMPU systems, followed by simulating their XRD and FTIR patterns, respectively. Non‐equilibrium ReaxFF simulations are implemented by using uniaxial box deformation technique to study response‐behavior of crystalline SMPU under tensile loading and during stress‐relaxation. The model and simulation scheme presented in this study demonstrates a robust theoretical pathway toward application‐dictated, on‐demand design of high‐performance SMPUs in applications such as soft robotics.

Afroz, Mohammad M.↗

B‐Staging and Crosslinking of Polycarbosilane at Room Temperature: Cure Mechanism and Properties

The viscosity of polycarbosilane (PCS) polymers is not advantageous for free forming. Various fillers and heat are used to obtain a formable paste. Due to the low yield stress, structures and preforms tend to slump or resin will flow out, especially during the curing of the polymer. B-staging of PCS allows for a more stable structure from room temperature until the full cure of the allyl groups occurs with heat. Additionally, hydrosilation is an effective means of crosslinking at room temperature and controlling viscosity. A network structure was formed in SMP-10 using silane and a vinyl-based crosslinker to bridge each polymer chain. Pt addition catalysts were added to enhance the increase in viscosity to make a lightly crosslinked gel to aid in thickening and forming and to improve the ceramic yield at 1000°C. In conclusion, this enables several options for controlling rheology and improving the properties of preceramic polymers to avoid slumping during curing.

inorganic polymers↗

Small Scale Creep Testing of 14YWT via In-situ Transmission Electron Microscopy Irradiation and Nanoindentation

The next generation of nuclear materials must withstand harsh operating conditions such as high temperatures and irradiation doses. Nanostructured ferritic alloys like oxide dispersion strengthened steels, especially 14YWT, have shown promise as a structural material to withstand these harsh operating conditions. For application, understanding the irradiation enhanced creep of the structural components is fundamental to evaluating the service life in a reactor. Challenges with evaluating irradiation enhanced creep are related to the limited space in nuclear reactors and the expense of conducting post irradiation experiments on irradiated cladding. Ion irradiations are considered to expedite irradiation testing, but such experiments have restricted depth of penetration into the material, limiting the ability to characterize changes to material properties after irradiation. Small scale mechanical testing can be used with ion beam irradiations as a potential avenue to evaluate the irradiation enhanced creep of materials. In this study, in-situ transmission electron microscopy nanopillar creep studies on 14YWT were performed and simultaneously ion beam irradiated with 2.8 MeV Au4+ ions. It was observed that the ion beam irradiation did increase the measured strain rate of the materials. In addition, ex-situ nanoindentation creep studies were performed over a range of temperatures on control 14YWT, and it was observed that there was a change in the deformation mechanism between 873 K and 1073 K that agrees well with macro-scale mechanical testing. Furthermore, these results show promise for applying these techniques to nuclear materials in the future.

14 YWT↗

Heat activates the AAA+ HslUV protease by melting an axial autoinhibitory plug

At low temperatures, protein degradation by the AAA+ HslUV protease is very slow. New crystal structures reveal that residues in the intermediate domain of the HslU 6 unfoldase can plug its axial channel, blocking productive substrate binding and subsequent unfolding, translocation, and degradation by the HslV 12 peptidase. Biochemical experiments with wild-type and mutant enzymes support a model in which heat-induced melting of this autoinhibitory plug activates HslUV proteolysis.

59 BASIC BIOLOGICAL SCIENCES↗

Temperature effects on cobalt hydroxide–cobalt carbonate competitive growth on carbonate surfaces

Cobalt (Co), a critical metal essential for various environmental and industrial processes, undergoes speciation and immobilization in natural systems, primarily interacting with existing mineral surfaces. Understanding the underlying mechanisms of Co immobilization on abundant carbonate surfaces under different environmental conditions is critical for predicting Co mobility, availability, and recovery. In this study, we investigated the temperature-dependent competition between CoCO 3 and Co(OH) 2 formation on calcite (CaCO 3 ) and magnesite (MgCO 3 ) surfaces. Using X-ray photoelectron spectroscopy (XPS), scanning electron microscopy (SEM), and energy-dispersive X-ray spectroscopy (EDS), we analyzed carbonate substrates exposed to CoCl 2 solutions at varying concentrations (0–500 μM) and temperatures (22, 50, and 80 °C). Magnesite surfaces promoted CoCO 3 formation due to its low lattice mismatch with sphaerocobaltite (CoCO 3 ). However, this slow-growing CoCO 3 component was progressively outcompeted by Co(OH) 2 formation as the temperature and/or initial Co concentration increased. On calcite surfaces, the poor lattice mismatch between calcite and sphaerocobaltite led to Co(OH) 2 outcompeting CoCO 3 formation at all three temperatures. These findings provide critical insights into the roles of substrate composition, solution chemistry, and temperature in controlling Co speciation and mobility. They carry important implications for environmental transport, geochemical cycling, and industrial recovery of cobalt in carbonate-rich systems.

Calcite↗

A systematic approach to resolve high impedance of multifunctional energy storage composites

Previous work has proposed and characterized the structural and electrical performance of Multifunctional Energy Storage Composite (MESC) structures: structural elements with embedded lithium-ion batteries which were developed by the Structures and Composite Laboratory (SACL) at Stanford University. This work conducts a comprehensive parametric study over the design variables in the manufacturing process to determine the root cause of increased DC impedance compared to commercial pouch cell batteries. Several MESC samples were assembled under various controlled environmental temperatures and pressures. The samples underwent Hybrid Peak Pulse Characterization (HPPC) to approximate the DC impedance as a function of state of charge (SOC). Failure limits of the battery with respect to assembly temperature and pressure were tested, and an MESC manufacturing simulation model was constructed in Abaqus to validate the manufacturing limits. Samples assembled without enough temperature or pressure failed due to a lack of structural integrity or hermetic seal. Conversely, samples which underwent elevated temperatures and pressures resulted in high DC impedance due to nonuniform electrolyte wetting. This work resolves the primary concern of MESC by achieving comparable DC impedance to commercial pouch cells of the same chemistry and testing procedure.

25 ENERGY STORAGE↗

Warming rate drives microbial nutrient demand and enzyme expression during peat decomposition

Recent developments of enzyme-based decomposition models highlight the importance of enzyme kinetics with warming, but most modeling exercises are based on studies with a step-wise warming. This approach may mask the effect of temperature in controlling in-situ activities as in most ecosystems the rate of warming is more gradual than these step warming studies. We conducted an experiment to test the effects of contrasting warming rates on the kinetics of carbon (C), nitrogen (N), and phosphorus (P) degradation enzymes in subtropical peat soils. We also wanted to evaluate if the stoichiometry of enzyme kinetics shifts under contrasting warming rates and if so, how does it relate to the stoichiometry in microbial biomass. Contrasting warming rates altered microbial biomass stoichiometry leading to differing patterns of microbial demand for C vs. nutrient (N and P) and enzyme expression following the optimum foraging strategy. Activity (higher Vmax) and efficiency (lower Km) of C acquisition enzymes were greater in the step treatment; however, expressions of nutrient (N and P) acquiring enzymes were enhanced in the ramp treatment at the end of the experiment. In the step treatment, there was a typical pattern of an initial peak in the Vmax and drop in the Km for all enzyme groups followed by later adjustments. On the other hand, a consistent increase in Vmax and decline in Km of all enzyme groups were observed in the ramp treatment. These changes were sufficient to alter microbial identity (as indicated by enzyme Km and biomass stoichiometry) with two apparently different endpoints under contrasting warming rates. This observation resembles the concept of alternate stable states and highlights a need for improved representation of warming effects on enzymes in decomposition models. Using peat soils of Florida Everglades, here we have demonstrated that contrasting warming rates can influence the dynamics of microbial and enzymatic kinetics. Hence, we suggest that future laboratory and field warming studies could consider our approach to accurately represent microbial and enzymatic kinetics in biogeochemical models.

59 BASIC BIOLOGICAL SCIENCES↗

Heat losses associated with the upward flow of air, water, CO 2 in geothermal production wells

This present work reports on the heat losses associated with the upward flow of hot air, water, and CO 2 in a production well. The heat losses considered here are the frictional heat loss, the gravitational heat loss, the Joule-Thomson effect, and the conduction heat loss to the surrounding rock formation. These heat losses were characterized using the mass flow rate, the operation time as variable parameters while the surrounding formation was assumed to have constant properties with a linear geothermal gradient. The results show that, the frictional heat loss was small while the influences of the others depended on the flow conditions and the operation time. For water, the Joule-Thomson effect was a heating effect and its magnitude was comparable to that due to the gravitational effect. The conduction heat loss was dominant for all situations. For air as well as CO 2 , the Joule-Thomson effects were the cooling effects. For low mass flow rates, the conduction heat loss was the dominant heat loss during the initial stages of the operation and the combined heat losses due to the gravitational and the Joule-Thomson effects became dominant during the later times. For high mass flow rates, throughout the operation life time, the gravitational and the Joule-Thomson effects were the dominant heat losses that control the temperature of air and CO 2 in the production well.

15 GEOTHERMAL ENERGY↗

Experimental measurements of fuel and water crossover in an active DMFC

This work measured polarization curves as well as the high-frequency resistance of active direct methanol fuel cell (DMFC) operates at around 80 °C with active controls of temperature, methanol concentration, airflow rate, and relative humidity. The relative humidity of the air did not have noticeable impacts on the fuel cell unless the operating temperature was near the evaporation temperature of water (100 °C). The hydrophobic water management layer (WML) between the membrane electrode assembly (MEA) and cathode air channel increases the mass transfer resistance and improves the water retention in MEA. Adding a WML increased the peak power density, decreased the ohmic resistance, and improved the fuel efficiency of the fuel cell, especially when it operated near 100 °C. This study also quantitatively measured methanol and water crossover as well as the fuel efficiency at different operating currents. The fuel efficiency increased significantly with the increase of the current density. Using a hydrophobic fuel management layer (FML) between the anode fuel channel and MEA reduced the fuel and water crossover rates and increased the ohmic resistance due to the decrease of the water content of the Nafion membrane. The FML improved fuel efficiency by reducing the methanol crossover. The combination of the FML and WML enabled the steady operation of DMFC using highly concentrated methanol solutions (up to 75 wt%).

08 HYDROGEN↗