Exhaust gas of an automotive fuel cell is enriched with water vapour and has a pressure potential which can be utilized by a turbine. The gas expansion in the turbine leads to droplet nucleation and condensation. This results in a release of latent heat and a decrease of the gaseous mass flow which has a considerable influence on the turbine performance. This study aims to numerically investigate the influence of these phenomena on the performance map of the radial turbine of an automotive fuel cell turbocharger. For this purpose, the classical nucleation theory and Young’s droplet growth law are integrated into an Euler-Lagrange approach. The results show an almost linear relation between the pressure ratio and the condensation while the specific aerodynamics of an operating point has only a minor influence. At 80 % relative humidity of the inflow, the investigated turbine showed condensation above a total-to-static pressure ratio of 1.8. Condensation leads to thermal throttling of the turbine and to a temperature increase of the rotor outflow of up to 50 K. Increasing humidity of the inflow increases the power output, but condensation losses reduce the efficiency.

Radial turbines used in automotive fuel cell turbochargers operate with humid air. The gas expansion in the turbine causes droplets to form, which then grow through condensation. The associated release of latent heat and decrease in the gaseous mass flow strongly influence the thermodynamics of the turbine. This study aims to investigate these phenomena. For this purpose, the classical nucleation theory and Young’s growth law are integrated into a Euler–Lagrange approach. The main advantages of this approach are the calculation of individual droplet trajectories and a full resolution of the droplet spectrum. The results indicate an onset of nucleation at the blade tip and in the tip gap, followed by nucleation over the entire blade span, depending on the humidity at the turbine inlet. With a saturated turbine inflow, condensation causes the outlet temperature to rise to almost the same level as at the inlet. In addition, condensation losses reduce the efficiency and the latent heat released by condensation leads to significant thermal throttling.

Cathode systems of proton exchange membrane fuel cells are tasked with providing compressed air for the fuel cell stack. The exhaust gas from the fuel cell has a pressure potential which can be utilised in a turbine to partially power the compressor. Therefore, a radial compressor and a radial turbine are often combined with an electric motor to form an electric fuel cell turbocharger. The exhaust gas used to operate the turbine is humid and hence prone to condensation. Previous studies on such condensation only investigated a turbine segment and neglected the volute. This study overcomes this simplification and analyses the aerodynamics of the full-annulus flow of volute, stator and rotor. The focus is set on the effect of the circumferential asymmetry on the occurrence and strength of condensation in the turbine rotor. The effect of variations of the rotational speed is also investigated. The main finding is, that such asymmetries or speed changes can have a significant effect for operating points for which they are able to determine the occurrence of condensation. Operating points with no or with certain condensation are less affected.

High aspect ratio aircraft have a significantly reduced induced drag, but have only limited installation space for control surfaces near the wingtip. This paper describes a multidisciplinary design methodology for a morphing aileron that is based on pressure-actuated cellular structures (PACS). The focus of this work is on the transient dynamic system behavior of the multi-functional aileron. Decisive design aspects are the actuation speed, the resistance against external loads, and constraints preparing for a future wind tunnel test. The structural stiffness under varying aerodynamic loads is examined while using a reduced-order truss model and a high-fidelity finite element analysis. The simulations of the internal flow investigate the transient pressurization process that limits the dynamic actuator response. The authors present a reduced-order model based on the Pseudo Bond Graph methodology enabling time-efficient flow simulation and compare the results to computational fluid dynamic simulations. The findings of this work demonstrate high structural resistance against external forces and the feasibility of high actuation speeds over the entire operating envelope. Future research will incorporate the fluid–structure interaction and the assessment of load alleviation capability.

A mobile fuel cell systems power output can be increased by pressure amplification using an electric turbocharger. These devices are subject to frequent transient manoeuvres due to a multitude of load changes during the mission in automotive applications. In this paper, the authors describe a simulation approach for an electric turbocharger, considering the impact of moist air and condensation within the cathode gas supply system. Therefore, two simulation approaches are used: an iterative simulation method and one based on a set of ordinary differential equations. Additional information is included from turbine performance maps taking into account condensation using Euler–Lagrange CFD simulations, which are presented. The iterative calculation approach is well suited to show the impact of condensation and moist air on the steady state thermodynamic cycle and yields a significant shift of the steady state operating line towards the surge line. It is shown that a substantial risk of surge occurs during transient deceleration manoeuvres triggered by a load step.