Open Competition 1 - Electronics and Photonics

High-Power-Density Solid Oxide Fuel Cells for Aerospace Applications

Sponsor: NexTech Materials, Ltd.

• Project Performance Period: 10/1/2004 - 9/30/2007
• Total project (est.): $2,549,755.00
• Requested ATP funds: $1,999,966.00

Fuel cells, long used to provide electrical power for space missions, could provide clean, affordable energy for many other airborne applications. Solid oxide fuel cells (SOFCs), which convert chemical energy directly to electrical energy, would be more efficient than other means of generating electricity onboard aircraft. SOFCs offer advantages over other fuel cell designs because they operate at high temperatures and can use hydrocarbon-based fuels. However, existing SOFCs have inadequate power density and durability for use in commercial and military aircraft. To meet demanding aerospace requirements, NexTech Materials Ltd. proposes to develop a lightweight SOFC that offers five times the power density of state of the art and is easier to make, more durable, and tolerant of a wider range of temperatures and fuels than current cells. The higher power density will be achieved in part by using a compact, planar stack configuration and eliminating costly metal gas-channel interconnects that rob power through electrical contact losses. The technical risk is high because numerous innovations are needed in ceramic cell and stack fabrication, and because the use of sulfur-laden jet fuels has not been demonstrated with the proposed architecture. The ATP funding is necessary because venture capital and aerospace companies require a demonstration of feasibility before investing in unproven technology. NASA Glenn Research Center (Cleveland, Ohio) will support the project in the areas of materials development, cell/stack fabrication, and single-cell testing. SOFCo-EFS Holdings LLC (Alliance, Ohio) will support the project with testing of single cells and stacks under application-specific conditions. If successfully developed, the new technology could reduce auxiliary fuel usage by 70 percent on the ground and 40 percent in flight, and also enable aircraft designs that rely more heavily on electricity and that are lighter and more reliable. Other applications could include cars and trucks, military applications such as field generators and surveillance robots, and stationary power units for buildings.

For project information:

Jonathon Foreman, (614) 842-6606
foreman@nextechmaterials.com

ATP Project Manager

Gerald Castellucci, (301) 975-2435
gerald.castellucci@nist.gov