Thermoplastic Forming of Bulk Metallic Glass Nozzles for High-Pressure, Low-Temperature Hydrogen Fueling
Strong environmental concerns related to an extensive use of fossil fuels lead to a more active development of vehicles that use alternative fuels. Hydrogen is one such fuel that has the potential to be a cheaper, more efficient and cleaner alternative to gasoline. The cost and reliability of hydrogen dispensing nozzles are identified to be some of the critical barriers to the viability of the hydrogen infrastructure. In this project, we are proposing to develop highly reliable nozzles for high-pressure, low-temperature hydrogen gas filling using bulk metallic glass technology. Use of the BMG technology is expected to improve the reliability, reduce leakage, and reduce the cost of hydrogen nozzles. In Phase I, Supercool Metal evaluated hydrogen compatibility for several BMG alloys, identified fabrication techniques using thermoplastic forming processes, assessed economics and developed a technological path for production of BMG hydrogen nozzles. The key to evaluating the viability of BMGs for hydrogen nozzle applications is to establish an understanding of the materials’ behavior in a hydrogen environment and the feasibility of fabricating BMGs into a hydrogen nozzle geometry through thermoplastic forming techniques. In Phase I, we have performed literature research and analysis to evaluate the previously reported studies on hydrogen-BMGs interactions. Based on this analysis and thermoplastic forming abilities, we selected three BMG alloys for hydrogen compatibility tests to identify mechanical properties of the selected BMGs under a hydrogen gas pressure of 10MPa. The main conditions for the manufacturing technique through the thermoplastic forming process were also determined. As a starting point for the nozzle design, we estimated the geometrical requirements for the BMG nozzle that complies with safety standards for hydrogen refueling. Based on the selected alloy’s chemistry and the nozzle geometry, we have designed a thermoplastic forming process that can be used for fabrication of a nozzle. Lastly, the economics of manufacturing BMG nozzles for hydrogen refueling was assessed, confirming the potential of the TPF technology to significantly reduce the cost of nozzle and to achieve improvement in reliability and performance. In Phase II of the project, we plan to produce a prototype nozzle and conduct all the standardized testing required for a hydrogen fueling protocol in partnership with a commercial developer. We also plan to develop a specialized equipment and optimize TPF fabrication processes that can be used for a larger volume production of BMG hydrogen refueling nozzles beyond Phase II. This presents a unique and transformative technological approach that will increase the competitive advantage of the U.S. in this field and accelerate a wider adoption of hydrogen fuel cell vehicles.
- Research Organization:
- Supercool Metals LLC
- Sponsoring Organization:
- USDOE Office of Science and Technology (ST)
- DOE Contract Number:
- SC0019861
- OSTI ID:
- 1657250
- Type / Phase:
- SBIR (Phase I)
- Report Number(s):
- DOE-SCM-19861
- Country of Publication:
- United States
- Language:
- English
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