Electrical shorting through the proton exchange membrane (PEM) is a form of early failure commonly found in PEM fuel cells. In order to improve the durability and thus the commercial potential for PEM fuel cells, this form of failure must be understood and mitigated. This research investigates whether complete penetration is the most likely cause of shorting and establishes general parameters (force, contact pressure, temperature, and time) that lead to shorting in a typical PEM material, Nafion® NRE211. Data was obtained from a novel indentation apparatus that was coupled with an electrical circuit to assess the force and depth of penetration at which shorting occurs in a PEM at temperatures ranging from 70ï °C to 100ï °C. The results show that shorting occurs when full penetration is reached, based on both displacement at shorting, and resistance of the electrical circuit at shorting. In addition, a finite element model was created in a commercial finite element tool (Abaqus) in an attempt to predict time to penetration under loads and geometric configurations typically found in PEM fuel cells. The finite element model was investigated for use with standard Abaqus material modules (e.g. two-layer viscoplastic and hyperelastic-viscoelastic) describing Nafion® behavior. The results suggest that the standard material models do not sufficiently describe Nafion® behavior in this particular application and suggest the need for alternative material models that capture both the viscous and plastic nature of Nafion®. / Master of Science

The goals of the research documented in this thesis were the design, construction, modeling, and validation of a fuel cell hybrid electric vehicle based a conversion of a five-passenger production sedan. Over 60 engineering students working together as the Hybrid Electric Vehicle Team of Virginia Tech (HEVT), integrated a proton exchange membrane fuel cell system into a series hybrid electric vehicle. This design produced an efficient and truly zero-emission vehicle. This 1997 Chevrolet Lumina sedan, renamed ANIMUL H2, carries this advanced powertrain, using an efficient AC induction drivetrain, regenerative braking, compressed hydrogen fuel storage, and an advanced lead-acid battery pack for peak power load leveling. The vehicle weighed 2000 kg (4400 lb) and achieved a combined city/highway fuel economy of 9L/100 km or 26 mpgge (miles per gallon gasoline equivalent, charge depleting, state of charge corrected). A model of the vehicle was developed using ADVISOR, an Advanced Vehicle Simulator that tracks energy flow and fuel usage within the vehicle drivetrain and energy conversion components. The vehicle was tested using the Environmental Protection Agency city and highway driving cycles to provide data for validation of the model. Vehicle data and model results show good correlation at all levels and show that ADVISOR has the capability to model fuel cell hybrid electric vehicles. To make techniques proven by this work more versatile for real world application, VT worked with engineers at the National Renewable Energy Laboratory to develop a 'generic' version of this fuel cell system model that was released to the public in ADVISOR 2.2. This generic model correlates well to test data and incorporates both fuel cell stack and subsystem models. This feature allowed HEVT to predict the benefits of load following subsystem control, showing a 40% fuel economy improvement. / Master of Science

Fuel cell system models are key tools for automotive fuel cell system engineers to properly size components to meet design parameters without compromising efficiency by over-sizing parasitic components. A transient fuel cell system level model is being developed that includes a simplified transient thermal and parasitics model. Model validation is achieved using a small 1.2 kW fuel cell system, due to its availability. While this is a relatively small stack compared to a full size automotive stack, the power, general thermal behavior, and compressor parasitics portions of the model can be scaled to any number of cells with any size membrane area. With flexibility in membrane size and cell numbers, this model can be easily scaled to match full automotive stacks of any size. The electrical model employs a generalized polarization curve to approximate system performance and efficiency parameters needed for the other components of the model. General parameters of a stack's individual cells must be known to scale the stack model. These parameters are usually known by the time system level design begins. The thermal model relies on a lumped capacity approximation of an individual cell system with convective cooling. From the thermal parameters calculated by the model, a designer can effectively size thermal components to remove stack thermal loads. The transient thermal model was found to match experimental data well. The steady state and transient sections of the curve have good agreement during warm up and cool down cycles. In all, the model provides a useful tool for system level engineers in the early stages of stack system development. The flexibility of this model will be critical for providing engineers with the ability to look at possible solutions for their fuel cell power requirements. / Master of Science

The metallic interconnect of a solid oxide fuel cell (SOFC) contains chromium in order to protect the metal from the corrosive environment in the fuel cell. Unfortunately, the chromium introduces chemical instability in the cathode as it migrates from the interconnect to the pores in the cathode. A model was developed previously in Asinari et al. [1] and Kasula et al [2] to model the flow of particles in a fuel cell electrode. To learn more about the migration of the chromium, the previous code is modified in this thesis work to include the effects of the chromium. The model uses Kinetic Theory to simulate the fuel cell at a mesoscopic scale. The discretized form of the Lattice Boltzmann equation is modified for enhanced performance and for use on a parallel processing system. With the new model, the migration of the chromium in the cathode and the performance degradation of the fuel cell are predicted. / Master of Science

Micro air vehicles (MAVs) are small remote controlled aircraft used by military personnel for reconnaissance and are currently powered by batteries. The MAVs rely on the battery for propulsion, navigation, and reconnaissance equipment. The thrust of this research is to develop a fuel cell system capable of higher power densities, higher power to weight ratios, and increased overall power output than the batteries in use today. To this end, a feasibility study is first conducted to determine if fuel cells could be used to replace batteries as the MAV power source and what fuel cell configurations would show the best performance. Hydrogen, methanol, and formic acid fuel cells are considered, using a conventional flat-plate design and a novel micro-tubular design. Several micro-tubular fuel cells (MTFCs) are tested to show that these cells are a possibility for power production in MAVs. Those tested are developed and improved in collaboration between Luna Innovations, Inc. and the Center for Energy Systems Research at Virginia Tech and then manufactured by Luna Innovations, Inc. Also, an isothermal, lumped-parameter (LP) model for MTFCs is developed to predict behavior. The use of this LP model aids in understanding the dominant losses of the cell and ways of improving cell performance. Results from the feasibility study indicate that by using methanol powered MTFCs a 50% increase in overall energy output is possible, while also decreasing the mass of the power production system. Through testing and an iterative design process, an increase of three orders of magnitude of the maximum power production of the MTFCs constructed by Luna Innovations, Inc., has been realized. Results of the LP MTFC model are compared with the experimental results from the MTFC testing and tubular cells from the literature. / Master of Science

Fuel cells typically produce low-voltage high-current output because their individual cell voltage is low, and it is nontrivial to balance for a high-voltage stack. In addition, the output voltage of fuel cells varies depending on load conditions. Due to the variable low voltage output, the energy produced by fuel cells typically requires power conditioning systems to transform the unregulated source energy into more useful energy format. When evaluating power conditioning systems, efficiency and reliability are critical. The power conditioning systems should be efficient in order to prevent excess waste of energy. Since loss is dissipated as heat, efficiency directly affects system reliability as well. High temperatures negatively affect system reliability. Components are much more likely to fail at high temperatures. In order to obtain excellent efficiency and system reliability, low-voltage high-current power conditioning systems should be carefully designed. Low-voltage high-current systems require carefully designed PCB layouts and bus bars. The bus bar and PCB trace lengths should be minimized. Therefore, each needs to be designed with the other in mind. Excessive PCB and bus bar lengths can introduce parasitic inductances and resistances which are detrimental to system performance. In addition, thermal management is critical. High power systems must have sufficient cooling in order to maintain reliable operation. Many sources of loss exist for converters. For low-voltage high-current systems, conduction loss and switching loss may be significant. Other potential non-trivial sources of loss include magnetic losses, copper losses, contact and termination losses, skin effect losses, snubber losses, capacitor equivalent series resistance (ESR) losses, and body diode related losses. Many of the losses can be avoided by carefully designing the system. Therefore, in order to optimize efficiency, the designer should be aware of which components contribute significant amounts of loss. Loss analysis may be performed in order to determine the various sources of loss. The system efficiency can be improved by optimizing components that contribute the most loss. This thesis surveys some potential topologies suitable for low-voltage high-current systems. One low-voltage high-current system in particular is analyzed in detail. The system is called the V6, which consists of six phase legs, and is arranged as a three full-bridge phase-shift modulated converter to step-up voltage for distributed generation applications. The V6 converter has current handling requirements of up to 120A. Basic operation and performance is analyzed for the V6 converter. The loss within the V6 converter is modeled and efficiency is estimated. Calculations are compared with experimental results. Efficiency improvement through parasitic loss reduction is proposed by analyzing the losses of the V6 converter. Substantial power savings are confirmed with prototypes and experimental results. Loss analysis is utilized in order to obtain high efficiency with the V6 converter. Considerations for greater current levels of up to 400A are also discussed. The greater current handling requirements create additional system issues. When considering such high current levels, parallel devices or modules are required. Power stage design, layout, and bus bar issues due to the high current nature of the system are discussed. / Master of Science

Catalyst layer modeling can be a useful tool for fuel cell design. By comparing numerical results to experimental results, numerical models can provide a better understanding of the physical processes occurring within the fuel cell catalyst layer. This can lead to design optimization and cost reduction. The purpose of this research was to compare, for the first time, a direct numerical simulation (DNS) model for the cathode catalyst layer of a PEM fuel cell to a newly developed experimental technique that measures the ionic potential through the length of the catalyst layer. A new design for a microstructured electrode scaffold (MES) is proposed and implemented. It was found that there is a 25%-27% difference between the model and the experimental measurements. Case studies were also performed with the DNS to compare the effects of different operating conditions, specifically temperature and relative humidity, and different reconstructed microstructures. Suggested operating parameters are proposed for the best comparison between numerical and experimental results. Recommendations for microstructure reconstruction, MES construction and design, and potential measurement techniques are also given. / Master of Science

In recent years government, academia and industry have been pursuing fuel cell technology as an alternative to current power generating technologies. The automotive industry has targeted fuel cell technology as a potential alternative to internal combustion engines. The goal of this research is to understand and quantify the impact and effects of low temperature operation has on the performance and efficiency of vehicle fuel cell systems through modeling. More specifically, this work addresses issues of the initial thermal transient known to the automotive community as "cold-start" effects. Cold-start effects play a significant role in power limitations in a fuel cell vehicle, and may require hybridization (batteries) to supplement available power. A fuel cell system model developed as part of this work allows users to define the basic thermal fluid relationships in a fuel cell system. The model can be used as a stand-alone version or as part of a complex fuel cell vehicle model. Fuel cells are being considered for transportation primarily because they have the ability to increase vehicle energy efficiency and significantly reduce or eliminate tailpipe emissions. A proton exchange membrane fuel cell is an electrochemical device for which the operational characteristics depend heavily upon temperature. Thus, it is important to know how the thermal design of the system affects the performance of a fuel cell, which governs the efficiency and performance of the system. This work revealed that the impact on efficiency of a cold-start yielded a 5 % increase in fuel use over a regulated drive cycle for the converted sport utility vehicle. The performance of the fuel cell vehicle also suffered due to operation at low temperatures. Operation of the fuel cell at 20 C yielded only 50% of the available power to the vehicle system. / Master of Science

No / Traditionally materials with the fluorite and perovskite structures have dominated the research in the area of oxide ion/proton conducting solid electrolytes. In such cases, the key defects are oxide ion vacancies, and conduction proceeds via a simple vacancy hopping mechanism. In recent years, there has been growing interest in alternative structure types, many of which contain tetrahedral moieties. For these new systems, an understanding of the accommodation of defects and the nature of the conduction mechanism is important for the optimisation of their conductivities, as well as to help target related structures that may display high oxide ion/proton conduction. Computer modelling studies on a range of systems containing tetrahedral moieties are presented, including apatite-type La9.33+xGe6O26+3x/2, cuspidine-type La4Ga2-xTixO9+x/2 and La1-xBa1+xGaO4-x/2. The type of anion defect (vacancy or interstitial), their location and the factors affecting their incorporation are discussed. In addition, modelling data to help to understand their conduction mechanisms are presented, showing novel aspects including the important role of the tetrahedral moieties in the conduction processes.

No / Traditionally materials with the fluorite and perovskite structures have dominated the research in the area of oxide ion/proton conducting solid electrolytes. In such cases, the key defects are oxide ion vacancies, and conduction proceeds via a simple vacancy hopping mechanism. In recent years, there has been growing interest in alternative structure types, many of which contain tetrahedral moieties. For these new systems, an understanding of the accommodation of defects and the nature of the conduction mechanism is important for the optimisation of their conductivities, as well as to help target related structures that may display high oxide ion/proton conduction. Computer modelling studies on a range of systems containing tetrahedral moieties are presented, including apatite-type La9.33+xGe6O26+3x/2, cuspidine-type La4Ga2¿xTixO9+x/2 and La1¿xBa1+xGaO4¿x/2. The type of anion defect (vacancy or interstitial), their location and the factors affecting their incorporation are discussed. In addition, modelling data to help to understand their conduction mechanisms are presented, showing novel aspects including the important role of the tetrahedral moieties in the conduction processes