Publications Details

Innovative Development Selection and Testing to Reduce Cost and Weight of Materials for BOP Components

Zimmerman, Jonathan A.; San Marchi, Christopher W.

The primary objective of this effort is to identify alloys to replace type 316/316L in hydrogen service for balance of plant (BOP) applications onboard fuel cell electric vehicles (FCEVs). Type 316/316L austenitic stainless steels are used extensively in hydrogen systems for their resistance to hydrogen embrittlement, which is attributed to the relatively high nickel content of type 316/316L alloys. Nickel content, however, drives the cost of austenitic stainless steels, thus type 316/316L alloys impose a cost premium compared to similar alloys with lower nickel content. Since the cost of BOP components is a large fraction of the cost of hydrogen fuel systems (even dominating the cost at low production volumes [1]), alternative materials are desired. In addition, type 316/316L alloys are relatively low strength, thus high-pressure components tend to be heavy to accommodate the stresses associated with the pressure loads. Higher-strength materials will reduce weight of the components (an added benefit for onboard components) and contribute to lower cost since less material is needed. However, engineering data to justify selection of lower cost and higher strength alloys for high-pressure hydrogen service are currently unavailable. Moreover, alloy design could enable low cost solutions to the specific needs of onboard hydrogen storage.