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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 19 records
All sourcesNASA NTRSDOE OSTI
DOE OSTI2025

Hydrogen Fuel Cell Electric Vehicles

A hydrogen fuel cell electric vehicle (FCEV) is two to three times more efficient than a comparable vehicle powered by an internal combustion engine running on gasoline. Because of their efficient operation, FCEVs can travel long distances with less fueling. An FCEV also produces clean tailpipe exhaust, emitting only water vapor and warm air. FCEVs have driving ranges of more than 300 miles per tank of hydrogen. Drivers can fuel their FCEVs in less than five minutes at a dispenser that looks and feels similar to gasoline dispensers except for the high-pressure gaseous connection.1 In addition, FCEVs are propelled by an electric motor, so they are very quiet, have very few moving parts and fewer fluids to change, and have minimal maintenance requirements overall.

ADVANCED PROPULSION SYSTEMS,HYDROGEN↗
DOE OSTI2025

Graphene reinforced UHMWPE fibers

Thermoplastic polymers are increasingly used in electric vehicles, hydrogen fuel cell vehicles, and other decarbonization applications due to their lightweight and formability. Higher-strength polymers are needed to supplant metals in the vehicle structure, thereby reducing mass and improving efficiency. Ultra-high molecular weight polyethylene (UHMWPE) fibers possess one of the highest strength-to-weight ratios of technical polymers, and further improvement via reinforcement by nanofillers, such as graphene, will expand their performance envelope. Here, in this work, UHMWPE/graphene nanocomposite fibers were gel spun and characterized for their morphological, microstructural, thermal, and mechanical properties. The addition of a low fraction of graphene improved the tensile strength of the fibers by 25% and tensile modulus by 32%. Differential scanning calorimetry showed an increase in melting temperature and degree of crystallinity, which indicates improved coordination of the molecular chains induced by the addition of graphene. The reinforcement also affected the cross-sectional shape of the fibers; the aspect ratio of the fibers’ elliptical shape declined with increasing graphene content showing the skeletal effect of the graphene nanofillers in the polymer matrix. The reinforcing effect of graphene declined above a threshold concentration, and theoretical modeling was applied to demonstrate that increased agglomerates led to reduced properties. This work demonstrates a simple, effective method to produce graphene-reinforced UHMWPE fibers and lays a foundation for understanding the potential for leveraging graphene to form ultra-high-performance nanocomposite fibers for myriad engineering applications.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Clean Cities and Communities Partnership 2023 Activity Report

This is the 2023 report for the Clean Cities and Communities (CC&C) partnership. It tracks the metrics that have been reported by individual coalitions and aggregated to the national level. It looks at the various outreach activities, grant activities, and implementation of clean transportation technologies. Such technologies include natural gas vehicles, electric vehicles, propane vehicles, hydrogen fuel cell vehicles, biodiesel, ethanol, idle reduction technologies, fuel economy improvement technologies, vehicle-miles-traveled reduction technologies, and off-road technologies. The CC&C partnership had an energy use impact of over 1 billion gallons in 2023 and reduced emissions by nine million tons. Outreach, engagement, and training activities increased 18% from last year.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗
DOE OSTI2025

Operational optimization for multi-functional charging station with electric and hydrogen-powered vehicles

The rapid adoption of electric vehicles (EVs) and hydrogen fuel cell vehicles (HFCVs), combined with global efforts to reduce carbon emissions, has accelerated the development of EV charging and hydrogen refueling stations. In response to this demand, this paper introduces the concept of Multi-Functional Charging Station (MFCS) that integrates power generation, EV charging, battery swapping, and hydrogen refueling. A comprehensive operational model is developed for the MFCS that couples electricity and hydrogen conversion and storage technologies to enhance infrastructure utilization and improve overall system efficiency. The model also considers multiple revenue streams, including participation in energy and ancillary markets. To validate the effectiveness of the proposed model and evaluate its performance, a series of numerical experiments are conducted with different charger numbers, different electricity purchase limits, and different charger allocations. Numerical results demonstrate that shared charger configurations can lead to 8.11 % improvement in operational profit by improving resource utilization and reducing the number of depleted batteries at the end of operations compared to allocated charger setups. By varying the number of chargers, sensitivity analysis identifies diminishing marginal returns beyond about 45 chargers, suggesting it as an optimal sizing point under current settings. The integration of electricity and hydrogen conversion is also explored under scenarios with limited external electricity purchases. In conclusion, these findings indicate that optimizing charger allocation and energy management can significantly enhance station productivity and profitability, ultimately supporting the broader adoption of electrified and hydrogen-based transportation solutions.

Charging station↗
DOE OSTI2026

Operational Simulation of Multi-Functional Charging Station for Sustainable Transportation

As transportation systems move toward electrification and decarbonization, multifunctional charging stations (MFCS) are emerging as key infrastructure for electric vehicles (EVs) and hydrogen fuel cell vehicles (HFCVs). This paper presents a simulation model of an MFCS that integrates solar photovoltaic (PV), wind power, battery storage, hydrogen (\mathrm{H}_{2}) production, dual-pressure \mathrm{H}_{2} storage, fuel cells, and dynamic grid interactions. The model simulates daily operations using 5 -minute resolution data to capture realtime variability in renewable energy (RE), demand, and electricity prices. A flexible dispatch algorithm dynamically allocates energy for EV charging, \mathrm{H}_{2} production, storage, and grid transactions while respecting system constraints. Results show that the MFCS effectively prioritizes RE usage, minimizes waste, meets diverse energy demands, and achieves net operational profit. The model serves as a valuable decision-support tool for designing and optimizing integrated clean energy hubs for zero-emission transportation.

Gbadegoye, Jeremiah [University of Tennessee, Knox↗
DOE OSTI2026

Toyota Highlander FCHV (CRADA CRD-12-00469 Final Report)

This project relates to the loan of four Toyota Mirai FCEV-adv vehicles to NLR to provide a load (vehicles to fill with hydrogen) to our fueling station research facility to study hydrogen fueling infrastructure performance using 700 bar precooled hydrogen at ESIF’s Hydrogen Infrastructure Testing and Research Facility (HITRF) facility.

33 ADVANCED PROPULSION SYSTEMS↗
DOE OSTI2025

High Efficiency and Transient Air Systems for Affordable Load-Following Heavy Duty Truck Fuel Cells

Hydrogen fuel cell powered vehicles are one of the potential paths to reducing vehicle emissions. An important subsystem of the hydrogen fuel cell system is an air handling system that provides the needed oxygen (in air) to react with hydrogen in the fuel cell stack for electric power generation. Today’s systems use an electric motor to power an air compressor that supplies oxygen to the fuel cell stack. This process requires significant electrical power and is the largest parasitic power loss in hydrogen fuel cell vehicles. In addition to parasitic power loss, hydrogen fuel cell systems often have reliability issues associated with the air handling system. Reliability is of significant concern for heavy duty applications (especially long-haul applications). This project aims to improve both the electrical power consumption and reliability of hydrogen fuel cell air handling systems to meet the needs of heavy duty on-highway vehicle applications.

08 HYDROGEN↗
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 OSTI2024

Reference Station Risk Assessment for Refueling Heavy-Duty Vehicles Using HyRAM+

The deployment of heavy-duty (HD) hydrogen fuel cell vehicles that are entering the market now is driving the need for expanded HD hydrogen refueling station infrastructure to meet demand. This expansion must prioritize safety and reliability, necessitating careful consideration of the associated risks. In this study, we use a light-duty (LD) hydrogen refueling station as a comparative tool to quantify the risks for a HD station, which is essentially a scaled-up version of a LD station.

08 HYDROGEN↗
DOE OSTI2026

Understanding Advanced Vehicle Technology Adoption Potential in Commercial Fleets Across Major Trucking Sectors

Adopting advanced vehicle technologies, such as battery-electric, hybrid, and hydrogen fuel cell vehicles, can be an effective strategy for reducing fleet owners' operating costs. However, different trucking sectors, such as private and for-hire carriers and short- or long-haul operations, may face unique challenges in adopting those vehicle technologies due to their own operational needs and budget constraints. Current studies on fleet-wide vehicle technology projections frequently overlook such sectoral differences and fail to capture variation in adoption potential across sectors. This study addresses this gap by analyzing the disparities in the total cost of ownership (TCO) and payback period (PBP) among a large and heterogeneous sample of fleet owners. It aims to understand the sectoral differences in the long-term potential for adopting advanced vehicle technologies. Utilizing the 2021 US Vehicle Inventory and Use Survey (US VIUS), which offers data on various commercial vehicle sectors, their operational patterns, and current vehicle assets, this research estimates the TCO and PBP for individual trucks over multiple future years. The results reveal variation in the cost-effectiveness of different vehicle technologies across trucking sectors, as well as the potential technology landscape in both the short and long term. The findings from this study can inform policymakers and practitioners on how to prioritize sectors with lower barriers for advanced vehicle technology adoption and support industries that face challenges in switching to advanced vehicles.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2025

Renewable Hydrogen to Vehicle (RH2V) – Operation Verification and Risk Mitigation Studies: Original Agreement (Modification 0) (CRADA Final Report)

Toyota has announced plans for commercial fuel cell vehicle deployment in 2015. To fully realize the benefits of fuel cell vehicles (zero emission with no performance loss in terms of vehicle range and capability), hydrogen produced efficiently from renewable sources is necessary. Most of the hydrogen fueling stations today utilize hydrogen reformed from natural gas (produced onsite or delivered). This enables more stations to be deployed cost-effectively within a network. Producing and using cost-effective renewable hydrogen in fuel cell vehicles will enable realization of the full potential. A viable option of green hydrogen that reliably delivers on the full suite of benefits for Toyota fuel cell vehicle drivers is needed. NREL is in a unique position to analyze and optimize renewable hydrogen production scenarios using the Energy Systems Integration Facility (ESIF), a facility that is specifically designed to evaluate renewable energy integration technologies. As the U.S. Department of Energy's (DOE) primary national laboratory for renewable energy and energy efficiency research and development, NREL has extensive knowledge of photovoltaic systems as well as alternative renewable technologies for efficient and reliable production of green hydrogen.

08 HYDROGEN↗
DOE OSTI2026

Agent-Based Simulation of Price-Demand Dynamics in Multi-Service Charging Station

As the adoption of electric vehicles and hydrogen fuel-cell vehicles grows, understanding how dynamic pricing strategies influence charging and refueling behaviors becomes crucial for optimizing local energy markets. This paper proposes a simulation-based analysis of a hydrogen-electricity integrated charging station that serves both types of vehicles. A multi-agent simulation framework is developed to model the interactions between vehicles and the station, incorporating price- and delay-sensitive behaviors in decision-making. The station can dynamically adjust energy prices, while vehicles optimize their charging or refueling choices based on their utility values. A series of sensitivity analyses are conducted to evaluate how electricity pricing, infrastructure capacity, and waiting behavior impact station performance. Results highlight that moderate electricity prices maximize user participation without sacrificing profit, infrastructure should be right-sized to demand to avoid over- or underutilization, and delay-toleration also affects service outcomes, which may reach the maximum service coverage at the threshold of 45 minutes.

Wang, Xudong [University of Tennessee, Knoxville (↗
DOE OSTI2026

Fleet Hydrogen Basics

Hydrogen is one transportation fuel option public and private heavy-duty vehicle fleets can consider. Heavy-duty hydrogen fuel cell electric vehicles provide the performance benefits of electric drivetrains (e.g., high instantaneous torque for heavy loads and performance improvements at high altitudes and on steep grades) and can contribute to air quality improvements in high-traffic areas. For some regions and duty cycles, hydrogen could be a better fit for heavy-duty fleets than current battery-electric options because of the increased range and faster fueling times.

30 DIRECT ENERGY CONVERSION↗
DOE OSTI2026

Novel Air System for 300 kW Heavy Duty Fuel Cell

Hydrogen fuel cell powered vehicles for heavy duty trucks is a potential path for reducing heavy duty vehicle emissions in the future. The air handling system delivers the proper amount of air (oxygen) to react with fuel (hydrogen) in the fuel cell to produce power. Air delivery requires significant power and is the largest parasitic loss for a 300 kW fuel cell. Today’s systems use an electric motor to power an air compressor that supplies oxygen to the fuel cell stack. In addition to parasitic power loss, hydrogen fuel cell systems often have reliability issues associated with the air handling system. Reliability is of significant concern for heavy duty applications (especially long-haul applications). This project aims to improve both the electrical power consumption and reliability of hydrogen fuel cell air handling systems to meet the needs of heavy duty on-highway vehicle applications. The air handling is provided by a twin vortices series (TVS) compressor in addition to adding a TVS expander to recover waste heat energy back into the compressor. The final configuration includes a 600 V, 39 kW motor connected with a single shaft to the compressor and expander. This configuration reduced the total electrical power consumption from 48.6 kW to 37 kW at full load, 27 kW to 9 kW at half load and 0.44 kW to 0.22 kW at idle. The response time requirement was to be less than 2 seconds while the final demonstration yielded 0.62 sec. The study includes additional technologies including water dosing into the compressor, a recuperator and elimination of the intercooler.

Reich, Evan [Eaton Corporation, Southfield, MI (Un↗
DOE OSTI2026

Cradle-to-Grave Lifecycle Analysis of U.S. Medium- and Heavy-Duty Vehicle-Fuel Pathways: A Greenhouse Gas Emissions Assessment of Current (2021) and Future (2035) Technologies

This study presents a cradle-to-grave lifecycle analysis of energy use and greenhouse gas (GHG) emissions for U.S. medium- and heavy-duty vehicles across current (2021) and future (2035) technologies using the Greenhouse gas, Regulated Emissions, and Energy use in Technologies (GREET) model with industry-vetted assumptions. Results vary across vehicle classes but point to common trends: today, battery electric vehicles (BEVs) offer significant (10–60%) GHG emissions reduction compared to diesel internal combustion engine vehicles and are the lowest emissions option per ton-mile of cargo movement, followed by hydrogen fuel cell electric vehicles (FCEVs) (5–50% emissions reduction). Emissions savings depend largely on the duty cycle and fuel economy of the vehicle type. Future vehicle technology advancements result in comparable emission reductions associated with BEVs and hydrogen FCEVs. Weight-limited BEV trucks see less per-ton-mile emissions reduction due to the impact of battery weight on increased vehicle weight and reduced payload capacity. By 2035, improvements in vehicle efficiency can reduce emissions across all powertrains. However, very low levels of emissions require switching vehicles’ use-phase fuel/energy to low-carbon fuels and electricity. Renewable diesel, e-fuels, hydrogen produced from natural gas with carbon capture and storage or renewables, and use of low-carbon electricity can all achieve over 70% reduction in GHG emissions from the current day diesel-based internal combustion engine vehicle.

alternative fuels↗
DOE OSTI2025

Autonomous Fueling System for Heavy-Duty Fuel Cell Electric Trucks

The motivation for this project stemmed from the challenges associated with rapidly refueling heavy-duty hydrogen fuel cell electric trucks (FCETs). Current manual refueling processes for fast refueling involve large, heavy equipment (e.g., hoses three times heavier than standard) and pose ergonomic risks and potential for equipment damage. The goal was to develop and test an autonomous fueling system to improve ergonomics, enhance safety, increase equipment durability through design improvements, and potentially speed up the fueling process. This project aimed to add to the understanding of autonomous systems in the context of heavy-duty hydrogen refueling, evaluating the technical effectiveness of potential concepts. A successfully developed system would benefit the public by facilitating the adoption of zero-emission heavy-duty transport, reducing reliance on manual labor for a physically demanding task, and potentially improving the safety and efficiency of hydrogen refueling infrastructure. The major accomplishment during the project's active period was the completion of the system-level architecture task. This involved establishing a detailed list of system requirements covering interfaces, environmental conditions, regulatory compliance, industry standards, safety, security, performance capabilities, and optional features. Five key use cases for the autonomous system were also identified. However, due to internal restructuring at Nikola, the necessary resources could not be allocated to continue the project. Consequently, Nikola opted to discontinue the project. The award was mutually terminated by Nikola and the DOE.

08 HYDROGEN↗
DOE OSTI2025

Hazard and Operability Analysis for Operating, Refueling, and Maintenance of Fuel Cell Electric Buses

​​Since hydrogen vehicles can be implemented in heavy-duty transportation applications such as buses, it is important to understand safety hazards and risks of hydrogen fuel cell electric bus (FCEB) and refueling technology. We conducted a hazard and operability analysis for FCEB operation/driving, refueling, and maintenance/inspection. We identified failure modes and consequences and defined a qualitative risk metric as the product of the likelihood of a failure and the severity of the worst-ca

08 HYDROGEN↗
DOE OSTI2025

Hydrogen and Electric Charging Infrastructure for Heavy-Duty Trucks: A Nationally Scalable Megaregion Assessment

Decarbonizing regional and long-haul freight is challenging due to the limitations of battery-electric commercial vehicles and infrastructure constraints. Hydrogen fuel cell medium- and heavy-duty vehicles (MHDVs) offer a viable alternative, aligning with the decarbonization goals of the Department of Energy and commercial entities. Historically, alternative fuels like compressed natural gas and liquefied propane gas have faced slow adoption due to barriers like infrastructure availability. To avoid similar issues, effective planning and deploying zero-emission hydrogen fueling infrastructure is crucial. This research develops deployment plans for affordable, accessible, and sustainable hydrogen refueling stations, supporting stakeholders in the decarbonized commercial vehicle freight system. It aims to benefit underserved and rural energy-stressed communities by improving air quality, reducing noise pollution, and enhancing energy resiliency. This research also provides a blueprint for replacing diesel in over-the-road Class 8 freight truck applications with hydrogen fueling solutions. The study focuses on the Texas Triangle Megaregion (I-45, I-35, and I-10), the I-10 corridor between San Antonio, TX, and Los Angeles, CA, and the I-5/CA-99 corridors between Los Angeles, CA, and San Francisco, CA. This area represents a significant portion of U.S. heavy-duty freight movement, carrying ~8.5% of the national freight volume. Using the OR-AGENT (Optimal Regional Architecture Generation for Efficient National Transport) modeling framework, the study conducts an advanced assessment of commercial vehicles, road and freight networks, and energy systems. The framework integrates data on freight mobility, traffic, weather, and energy pathways to deliver a region-specific, optimized vehicles powertrain architectures, infrastructure deployment solutions, operational logistics, and energy pathways. By considering all vehicle origin-destination pairs utilizing these corridors and all feasible fueling station location options, the framework's genetic algorithm identifies the minimum number and optimal locations of hydrogen refueling stations, ensuring no vehicle is stranded. It also determines fuel schedules and quantities at each station. A roadmap for station deployment based on multiple adoption trajectories ensures a strategic rollout of hydrogen refueling infrastructure.

Sujan, Vivek [ORNL] (ORCID:0000000269882342)↗