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Two types of air-cooled modular polymer membrane fuel cells (PEMFC) stacks with full equipment were constructed and investigated as components of hybrid power sources. The first, a 2-kW PEMFC stack, was assembled from two 1-kW PEMFC modules electrically connected in parallel and compared with a commercial PEMFC stack built from one 2-kW PEMFC module. The second, a 500-W PEMFC stack, was assembled with three modules connected in parallel. It was found that the two-module PEMFC stack was capable of operation with nominal power of 2 kW. Analysis of the distribution of the air cooling system in both modules was also conducted. The two-module PEMFC stack reduced hydrogen consumption compared to the reference 2-kW PEMFC stack consisting of only one module. The elaborated two-module PEMFC stack was successfully tested in a propulsion system designed to supply an electrical engine with a propeller. The electrical performance of the three-module PEMFC stack was tested separately as well as in a hybrid system in connection with a 5 s Li-Pol battery. It was found that the elaborated PEMFC stack was capable of operation with nominal power of 500 W and variable rapid dynamic electrical loads. It was also successfully tested as a power source to supply servomechanisms and other auxiliary devices.

The paper presents the current development of the AOS-H2 electric motor-glider project. The project encompasses the design and manufacture of an electric propulsion system (EPS) and a CF/epoxy airframe to be used as a flying test platform for the designed EPS. A 40-kW electric motor is supplied by a 10-kW PEM fuel cell stack and a Li-ion battery during run-up and ascent and by the fuel cell stack alone during steady flight. The airframe and the EPS have been completed; the results of bench tests of the EPS have proved that it meets the established requirements..

In this paper, the impact of partial substitution of calcium for barium in (Ba1-xCax) (M0.9Y0.1) O3, M = Ce, Zr on physicochemical properties of the powders and sintered samples was investigated. The powders, with various contents of calcium (x = 0, 0.02, 0.05, 0.1), were prepared by means of thermal decomposition of organometallic precursors containing EDTA. All of the BaCeO3-based powders synthesised at 1100 °C were monophasic with a rhombohedral structure, however, completely cubic BaZrO3-based solid solutions were obtained at 1200 °C. A study of the sinterability of BaZr0.9Y0.1O3 and BaCe0.9Y0.1O3-based pellets was performed under non-isothermal conditions within a temperature range of 25 to 1200 °C. The partial substitution of barium for calcium in the (Ba1-xCax) (M0.9Y0.1) O3, M = Ce, Zr solid solution improved the sinterability of the samples in comparison to the initial BaCe0.9Y0.1O3 or BaZr0.9Y0.1O3. The relative density of calcium-modified BaCe0.9Y0.1O3-based samples reached approximately 95 to 97 % after sintering at 1500 °C for 2 h in air. The same level of relative density was achieved after sintering calcium-modified BaZr0.9Y0.1O3 at 1600 °C for 2 h. Analysis of the electrical conductivity from both series of investigated materials showed that the highest ionic conductivity, in air and wet 5 % H2 in Ar, was attained for the compositions of x = 0.02 to 0.05 (Ba1-xCax)(M0.9Y0.1)O3, M = Zr, Ce. The oxygen reduction reaction on the interface Pt│BaM0.9Y0.1O3, M = Ce, Zr was investigated using Pt microelectrodes. Selected samples of (Ba1-xCax) (M0.9Y0.1)O3, M = Zr, Ce were tested as ceramic electrolytes in hydrogen-oxygen solid oxide fuel cells operating at temperatures of 700 to 850 °C.

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A 10 kW PEMFC (polymer exchange membrane fuel cell) stack consisting of two 5 kW modules, (A) and (B), connected in series with a multi-function controller unit was constructed and tested. The electrical performance of the V-shaped PEMFC stack was investigated under constant and variable electrical load. It was found that the PEMFC stack was capable of supplying the required 10 kW of electrical power. An optimised purification process via ‘purge’ or humidification, implemented by means of a short-circuit unit (SCU) control strategy, enabled slightly improved performance. Online monitoring of the utilisation of the hydrogen system was developed and tested during the operation of the stack, especially under variable electrical load. The air-cooling subsystem consisting of a common channel connecting two 5 kW PEMFC modules and two cascade axial fans was designed, manufactured using 3D printing technology, and tested with respect to the electrical performance of the device. The dependence of total partial-pressure drop vs. ratio of air volumetric flow for the integrated PEMFC stack with cooling devices was also determined. An algorithm of stack operation involving thermal, humidity, and energy management was elaborated. The safety operation and fault diagnosis of the PEMFC stack was also tested.

Two constructions of ~300W PEMFC stacks, cooled by different media, were analysed. An open-cathode ~300W PEMFC stack cooled by air (Horizon, Singapore) and a PEMFC F-42 stack cooled by a liquid medium (Schunk, Germany) were chosen for all of the investigations described in this paper. The potential for the design and construction of power sources involving fuel cells, as well as of a hybrid system (fuel cell-lithium battery) for mobile and stationary applications, is presented and discussed. The impact of certain experimental parameters on PEMFC stack performance is analysed and discussed.