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 an alternative fuel. Hydrogen is one such fuel that has the potential to be a cheaper, more efficient and a cleaner alternative to gasoline. With the predicted growth of fuel cell vehicles and hydrogen fueling stations, a reliable and cost-effective hardware for the hydrogen infrastructure is becoming very important. Specifically, the reliability and cost of nozzles for dispensing of hydrogen into fuel cell vehicles has been identified as one of the critical barriers. In this project, we are proposing to develop highly reliable nozzles for high-pressure, low- temperature hydrogen gas filling using bulk metallic glass technology. 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. Bulk metallic glasses (BMGs) are complex metal alloys that has superior mechanical properties and processability compared to that of conventional metals. Preliminary research suggests that bulk metallic glasses also have a higher resistance to hydrogen embrittlement due to lack of grain boundaries. In addition, bulk metallic glasses can be shaped effectively with processes similar to plastics to produce seamless nozzle-like shapes that will minimize leakage and improve reliability. Supercool Metals has been focused on development and commercialization of these unique forming processes for bulk metallic glasses and plans to use them in this project. Phase I of this project is focused on the overall assessment of BMGs for the use in hydrogen environment under pressures and temperatures associated with hydrogen refueling. It also aims to demonstrate the feasibility of using thermoplastic forming methods specifically for shaping nozzles with required performance and safety, and to conduct a techno-economic analysis of bulk metallic glass nozzles. Phase II of the project will be focused on fabrication of nozzle prototypes for hydrogen refueling stations and their testing. We will work with commercial partners, such as US-based producers of steel nozzles, developers of refueling stations, and fuel cell vehicle manufacturers. Phase III of this project will include further testing and qualifications of the products, development and building equipment for larger volume production and improving economics.