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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 OSTI2026

Detailed Simulation Datasets Quantifying U.S. DOE VTO/HFTO R&D Benefits Across Light- to Heavy-Duty Vehicles

For more than 20 years, Argonne National Laboratory’s Vehicle & Mobility Systems Department has assessed how R&D investments by the U.S. Department of Energy’s Transportation Technologies Office and Alternative Fuels and Feedstocks Office affect vehicle energy use and cost. The analyses are performed using Autonomie, Argonne’s full-vehicle simulation tool for energy consumption, performance, and cost. The study covers five time frames ranging from present day through 2050, with more than 30 vehicle classes and applications (10 light duty and >20 medium and heavy duty), as well as six powertrain configurations (conventional, start-stop, hybrid electric vehicle, plug-in hybrid electric vehicle, battery-electric vehicle, and fuel cell electric vehicle) and five fuels (gasoline, diesel, natural gas, hydrogen, and electricity). Low and high technology uncertainty scenarios have been considered to capture a realistic range of outcomes. The resulting datasets include the assumptions used (i.e., efficiency, $/kWh), vehicle-level data (power, energy, weight, and cost), and outputs such as energy consumption, manufacturer’s suggested retail price, and total cost of ownership. These data are critical to stakeholders working in transportation, technology assessment, and long-term R&D planning.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2025

Assessment of Heavy-Duty Fueling Methods and Components-Modeling and Analysis

The goal of the Assessment of Heavy-Duty Fueling Methods and Components project was to comprehensively assess heavy-duty (HD) fuel cell electric vehicle fueling protocols and their effects on techno-economic assessments (TEA) and total cost of ownership (TCO). The project leveraged and built upon ongoing international HD fueling protocols and fueling component development activities to deliver component performance assessments, modeling tools and methods evaluations, TEA of industry-selected protocol structures, and experimental validations of the strategies at the station scale. The effects of the protocols on the fueling times, station costs, and TCO were explored. Fueling time, which was influenced by temperature and protocol selection, had a large impact on the station cost due to component sizing and satisfying hourly demand. As the fleet size increased, the station cost was shown to exponentially decrease by achieving economies of scale. Technology year and fuel economy were the largest contributors to the TCO; however, the choice of fueling protocol had a minor impact on the TCO.

33 ADVANCED PROPULSION SYSTEMS↗
DOE OSTI2026

Assessment of Heavy-Duty Fueling Methods and Components

Chevron, NLR, ANL, and NextEnergy partnered in the development of a comprehensive assessment of heavy-duty (HD) fuel cell electric vehicle fueling protocols. The project leveraged and built upon existing international heavy-duty (HD) fueling protocols and fueling component development activities to deliver component performance assessments, modeling tools and methods evaluations, techno-economic assessments of industry-selected protocol structures and experimental validations of the strategies performed at NLR's HD hydrogen fueling station.

08 HYDROGEN↗
DOE OSTI2026

Autonomie Simulation Datasets in Support of U.S. DOT-NHTSA Advanced Vehicle Technology Research

Understanding how new vehicle technologies affect fuel economy and energy use is critical to the regulatory work performed by the U.S. Department of Transportation’s National Highway Traffic Safety Administration (NHTSA), which sets Corporate Average Fuel Economy (CAFE) standards under the Energy Policy and Conservation Act of 1975. In order to support this work, Argonne National Laboratory uses Autonomie, a full-vehicle simulation tool, to evaluate advanced powertrain architectures and their effects on vehicle energy consumption and performance. A wide range of vehicle classes has been assessed (i.e., internal combustion engine vehicles, hybrid electric vehicles, plug-in hybrid electric vehicles, battery-electric vehicles, and fuel cell electric vehicles), as well as the effects of various technology improvements such as lightweighting, aerodynamic refinements, and low-rolling-resistance tires. Simulations have been run across multiple drive cycles to capture fuel and electricity use under realistic operating conditions. The resulting datasets include detailed vehicle-level results, model assumptions, and validation reports, all of which have been made publicly available through NHTSA in support of the 2023 notice of proposed rulemaking covering light-duty vehicles for model years 2027 to 2035. These data are critical to stakeholders working in fuel economy regulation, vehicle technology assessment, and energy policy analysis.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2025

Regional Analysis for an Economically and Environmentally Viable Transition to Heavy-Duty Vehicles with Alternative Powertrains

The transportation sector is responsible for a significant portion of greenhouse gas emissions. Within the sector, truck freight is responsible for a third of the associated emissions. Alternative powertrains are seen as a viable approach to significantly reduce these emissions. Prior to making a large-scale transition, it is important to consider the following questions: will the power grid support a transition to alternative powertrains?; will the transition truly reduce carbon emissions?; and will the transition impose an unnecessary economic burden on companies within the industry? The answer to these questions, however, can vary by geography, maturity/capacity of the energy distribution network or predicted vehicle load. We focus on the latter two questions, investigating the variation in estimated total cost of ownership and carbon emissions across the United States at the zip code level for both heavy-duty battery electric vehicles and heavy-duty fuel cell electric vehicles. As a benchmark, we compare estimated emissions and costs of alternative powertrain vehicles to that of conventional heavy-duty vehicles powered by diesel internal combustion engines. This work highlights areas with electric grids primed for a transition to alternative powertrain vehicles, such as the Pacific Northwest, and areas that require further infrastructure investment in renewables, such as many of the Mountain states, Missouri, and Florida. Additionally, this work illustrates the current advantages in carbon emissions of battery electric vehicles compared to fuel-cell electric vehicles, while providing insights into required regional investments for narrowing the gap.

Goulet, Nate [ORNL] (ORCID:0000000237314965)↗
DOE OSTI2025

Total cost of ownership of vehicle electrification and fuel switching options for light-duty and heavy-duty vehicles

Projecting the transition from combustion engines to battery-based powertrains is complex becuase it involves numerous interdependent decisions. This study estimates total cost of ownership (TCO) to assess the economic viability of powertrain electrification, focusing exclusively on advances in vehicle and fuel technologies. Under two bounding technology-progress scenarios, we develop vehicle designs and fuel cost trajectories, which serve as inputs to TCO projections for selected classes from 2021 to 2050. We analyzed a small sport utility vehicle (SUV) to represent the light-duty vehicle (LDV) sector, and four medium- and heavy-duty vehicle (MHDV) classes: Class 6 box delivery, Class 8 drayage, Class 8 long-haul, and Class 8 transit bus. For each class, we compared the TCO of battery electric vehicles (BEVs) and fuel cell hybrid electric vehicles (FCHEVs) against conventional internal combustion engine vehicles (ICEVs). The results show that modern ICEVs generally have lower TCO; however, BEVs and FCHEVs could match or have lower TCOs than ICEVs over time, depending on technological progress. In LDVs, BEV300 is projected to deliver the lowest TCO by 2050, particularly under the high-progress scenario. In MHDVs, both BEVs and FCHEVs could become more cost-competitive than ICEVs by 2050 in the high-progress case. Beyond these results, the findings suggest further investigation is warranted for BEV charging infrastructure, FCHEV hydrogen refueling infrastructure, and MHDV charging strategies. In conclusion, these factors could reduce the fuel-cost share of TCO and enhance the competitiveness of BEVs and FCHEVs relative to ICEVs.

Battery electric vehicle↗
DOE OSTI2026

Levelized Cost of Dispensed Hydrogen for Heavy-Duty Vehicles

In this short technical report, we explore the range of levelized costs of dispensed hydrogen (H2) from hydrogen refueling (or fueling) stations (HRS) for H2 heavy-duty fuel cell electric vehicles (FCEVs) that are feasible in the 2030 timeframe. We explore different scenarios by varying hydrogen delivery distances, HRS sizes, HRS utilization rates, and economies of scale in the Hydrogen Delivery Scenario Analysis Model (HDSAM). Thus, we observe how the contribution to the levelized cost of each supply chain component changes.

30 DIRECT ENERGY CONVERSION↗
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

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

Electric Vehicle Basics (French Translation)

Electric vehicles (EVs) use electricity as their primary fuel or to improve the efficiency of conventional vehicle designs. EVs include all-electric vehicles, also referred to as battery electric vehicles (BEVs), and plug-in hybrid electric vehicles (PHEVs). In colloquial references, these vehicles are called electric cars, or simply EVs, even though some of these vehicles still use liquid fuels in conjunction with electricity. EVs are known for providing instant torque and a quiet driver experience. Other types of electric-drive vehicles not covered here include hybrid electric vehicles, which are powered by a conventional engine and an electric motor that uses energy stored in a battery that is charged by regenerative braking, not by plugging in, and fuel cell electric vehicles, which use a propulsion system similar to electric vehicles, where energy stored as hydrogen is converted to electricity by the fuel cell. This is the French translation of NREL/FS-5400-87125.

ADVANCED PROPULSION SYSTEMS,DIRECT ENERGY CONVERSI↗
DOE OSTI2026

SERA: A Hydrogen Infrastructure Capacity Expansion Model

The Scenario Evaluation and Regionalization Analysis (SERA) model is an infrastructure planning optimization model that can guide hydrogen production, delivery, and end-use investment decisions and accelerate the adoption of low-cost hydrogen at scale, whether for fuel cell electric vehicles or non-transportation applications. In this talk, we will review the SERA model objective function as well as the data inputs and outputs. We will also look at a SERA case study identifying potential dispensed costs of hydrogen along major refueling corridors throughout the United States. In addition to the SERA model, Justin will also discuss his recent work for the Office of Manufacturing and Energy Supply Chains on electrolyzer supply chain readiness, and his work for the Hydrogen Fuel Cell Technologies Office and Environmental Protection Agency on the levelized cost of dispensed hydrogen for heavy-duty trucking.

30 DIRECT ENERGY CONVERSION↗
DOE OSTI2026

Multi-Objective Boundary Analysis of Discrete and Integrated SiC FET Modular Non-inverting Buck and Boost Converters for Fuel Cell EVs

This paper presents a multi-objective analysis of discrete and integrated SiC FET-based non-inverting buck-boost converter modules for modular fuel cell electric vehicle (EV) systems. Two converter ratings, 60 kW and 90 kW, are evaluated for both implementations, scalable up to 420 kW and 450 kW, respectively. Performance is assessed across efficiency, volumetric and gravimetric power density, cost, thermal stress, and estimated lifetime, where lifetime is derived from SiC FET B10 power-cycling data and junction temperature variations at rated power. A normalized overall performance index combined with a Pareto-boundary framework is used to identify configurations that optimally balance competing objectives. Results show that most configurations lie on the Pareto front, providing balanced trade-offs, while certain high-power discrete (90 kW at 450 kW) and integrated (60 kW at 180−420 kW) configurations are dominated. In general, discrete modules are more favorable for lower-power modular systems due to higher power density and lower cost, whereas integrated modules become more advantageous at higher power levels due to improved thermal behavior and longer lifetime. These findings provide practical design guidance for scalable fuel cell converter architectures and highlight the importance of system-level trade-offs in modular power electronics design.

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

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

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↗