Lightweight fuel cell powerplant components program

A lightweight hydrogen-oxygen alkaline fuel cell incorporated into the design of a lightweight fuel cell powerplant (LFCP) was analytically and experimentally developed. The powerplant operates with passive water removal which contributes to a lower system weight and extended operating life. A preliminary LFCP specification and design table were developed along with a lightweight power section for the LFCP design, consisting of repeating two-cell modules was designed. Two, four-cell modules were designed incorporating 0.508 sq ft active area space shuttle technology fuel cells. Over 1,200 hours of single-cell and over 8,800 hours of two-cell module testing was completed. The 0.25 sq ft active area lightweight cell design was shown to be capable of operating on propellant purity reactants out to a current density of 600ASF. Endurance testing of the two-cell module configuration exceeded the 2,500-hour LFCP voltage requirements out to 3700-hours. A two-cell module capable of operating at increased reactant pressure completed 1000 hours of operation at a 30 psia reactant pressure. A lightweight power section consisting of fifteen, two-cell modules connected electrically in series was fabricated.