Abstract: A fluid storage tank includes a plurality of tank sub-units disposed in an array. Each tank sub-unit of the plurality of tank sub-units has an aperture defined in at least one wall overlapping with another aperture defined in at least one adjacent tank sub-unit of the plurality of tank sub-units. Each tank sub-unit of the plurality of tank sub-units is in fluid communication with a single outlet port for selectively extracting a stored fluid from the tank. Each of the plurality of tank sub-units is in fluid communication with a single fluid fill port. The array of tank sub-units is tessellated into a three-dimensional volume. A shell is disposed in contact with a plurality of the tank sub-units to envelop the array. The single outlet port and the single fluid fill port pass through the shell.

Abstract: A composite pressure vessel includes a liner to contain a pressurized fluid and a composite layer formed on at least a portion of an exterior surface of liner. The composite layer includes a third generation advanced high strength steel filament reinforcement embedded in a polymer matrix.

Abstract: A method of operating a vehicle powertrain includes determining a selected powertrain operational mode. A demand fraction is determined. An internal combustion engine (ICE) is to output a maximum power when a gaseous fuel is conveyed to an injector of the ICE at a source pressure greater than a cutoff pressure. The source pressure in a container in fluid connection with the injector is determined. The gaseous fuel is received at the source pressure by the injector to inject the gaseous fuel into the ICE for combustion in response to the source pressure, demand fraction, or selected powertrain operation mode meeting a first set of criteria. The injector is prevented from injecting the gaseous fuel into the ICE and the powertrain is driven from an alternative power source in response to the source pressure, demand fraction, or selected powertrain operation mode meeting a second set of criteria.

Abstract: A fluid storage tank includes a plurality of tank sub-units disposed in an array. Each tank sub-unit of the plurality of tank sub-units has an aperture defined in at least one wall overlapping with another aperture defined in at least one adjacent tank sub-unit of the plurality of tank sub-units. Each tank sub-unit of the plurality of tank sub-units is in fluid communication with a single outlet port for selectively extracting a stored fluid from the tank. Each of the plurality of tank sub-units is in fluid communication with a single fluid fill port. The array of tank sub-units is tessellated into a three-dimensional volume. A shell is disposed in contact with a plurality of the tank sub-units to envelop the array. The single outlet port and the single fluid fill port pass through the shell.

Abstract: A bipolar plate to reduce electrical contact resistance between the plate and a diffusion layer used in a fuel cell. The opposing surfaces of the plate define flow channels with upstanding lands interspersed between them. The lands of the plate form an electrically-conductive contact with a diffusion layer in the fuel cell. At least a portion of the electrically-conductive contact is made up of a nickel-based alloy that reduces the contact resistance between the plate and the diffusion layer as a way to achieve improved electric current density. In one form, the alloy can be used as the primary material in the plate, while in another, it can be used as a coating deposited onto a conventional stainless steel plate.

Abstract: A tank for storing compressed natural gas (CNG) for fueling an automotive vehicle engine. The tank includes a container body for containing the CNG at a service pressure rating from about 20 MPa (megapascals) to about 30 MPa, the container body being formed from a single piece. The container body includes a head end region, a terminal end region distal to the head end region, and an intermediate region extending therebetween. The terminal end region and the head end region define an axial length of the container body. The container body is formed from an aluminum alloy. A valve member is operatively connected to, and in fluid communication with the container body via an opening defined in a wall of the container body. The container body wall has a thickness ranging from about 3 mm to about 10 mm.

Abstract: A method of storing and using natural gas (NG) in a vehicle includes selecting a vehicle having an NG tank for fueling an engine of the vehicle. The tank service pressure rating is 3600 psi (pounds per square inch) and an NG adsorbent is in the tank. A first quantity of NG is transferred into the tank from a first source having a first source pressure less than 725 psi. The adsorbent adsorbs a portion of the NG. After transferring the first quantity of NG, the engine is operated until NG is desorbed and consumed by the engine. NG is transferred into the tank from a second source to fill the tank to a second tank pressure of about 3600 psi. The adsorbent adsorbs some of the NG. After transferring the second quantity of the NG, the engine is operated until NG is desorbed and consumed by the engine.

Abstract: A thermal management system for a natural gas tank includes a container, and a cooling mechanism operatively positioned to selectively cool the container. A method for minimizing a loss of natural gas storage during refueling is also disclosed herein. In an example of the method, a cooling mechanism, which is operatively positioned to selectively cool a container of a natural gas storage tank, is initiated prior to a refueling event. This cools the container to a predetermined temperature.

Abstract: A natural gas storage system includes a container, a natural gas adsorbent positioned in the container, and a heating mechanism operatively positioned to selectively thermally activate the adsorbent. A method for improving efficiency of the natural gas storage system is also disclosed. A predetermined percentage of a capacity of the container for natural gas remaining in the container is identified. In response, a heating mechanism operatively positioned to selectively thermally activate the adsorbent is initiated. The adsorbent is heated and buffer adsorbed gas is released from the adsorbent.

Abstract: A method for increasing capacity of a natural gas (NG) tank. The method includes selecting a container with a service pressure rating of about 3,000 or 3,600 psi. An NG adsorbent is in the container. The container has a maximum fill capacity. The method further includes cooling the adsorbent by Joule-Thomson cooling during filling of the container with NG from a filling source at greater than 3,600 psi. The container is filled to the maximum fill capacity at a fill rate to prevent a bulk temperature of the adsorbent from rising more than about 5° C. above an ambient temperature. A rate of heat transfer from the tank is less than a rate of heating from compression of the NG and adsorption during the filling. The NG adsorbent adsorbs a higher amount of NG than it would at higher than 5° C. above ambient.

Abstract: A fluid storage tank includes a plurality of tank sub-units disposed in an array. Each tank sub-unit of the plurality of tank sub-units has an aperture defined in at least one wall overlapping with another aperture defined in at least one adjacent tank sub-unit of the plurality of tank sub-units. Each tank sub-unit of the plurality of tank sub-units is in fluid communication with a single outlet port for selectively extracting a stored fluid from the tank. Each of the plurality of tank sub-units is in fluid communication with a single fluid fill port.

Abstract: A bipolar plate used in a fuel cell and a method of making a bipolar plate. The sheet is made from a ferritic or austenitic stainless steel, and defines an undulated surface pattern such that the patterned sheet may be formed into the bipolar plate. In one configuration, a stamping or related metal forming tool operation will further deform the patterned sheet into the bipolar plate shape such that the wall thickness is substantially uniform throughout the surface. In this way, there is a substantial reduction in stretching/thinning/necking at an intersection between bends and side walls that define the undulations of the pattern. In one form, the pattern defines a repeating serpentine shape. In a particular embodiment, the bends may include surface modifications to reduce the effects of sheet-to-tool misalignment.

Abstract: A bipolar plate used in a fuel cell and a method of making a bipolar plate. The sheet is made from a ferritic or austenitic stainless steel, and defines an undulated surface pattern such that the patterned sheet may be formed into the bipolar plate. In one configuration, a stamping or related metal forming tool operation will further deform the patterned sheet into the bipolar plate shape such that the wall thickness is substantially uniform throughout the surface. In this way, there is a substantial reduction in stretching/thinning/necking at an intersection between bends and side walls that define the undulations of the pattern. In one form, the pattern defines a repeating serpentine shape. In a particular embodiment, the bends may include surface modifications to reduce the effects of sheet-to-tool misalignment.

Abstract: A die for use in a sheet metal forming process includes a die material having a surface. A plurality of depressions is formed in a predetermined portion of the surface, where each of the plurality of depressions has a predetermined diameter and depth. Interaction of a surface of a sheet metal blank with i) the plurality of depressions, and ii) a solid forming lubricant, including particles of an average predetermined size and distribution, disposed on one of the die material surface or the sheet metal blank surface substantially reduces adhesion between the sheet metal blank surface and the die material surface during the sheet metal forming process.

Abstract: A metal forming process involves applying a lubricant, formed from a vitreous enamel mixed with particles of boron nitride, to at least one surface of a sheet metal blank, and without pre-heating the sheet metal blank, placing the sheet metal blank having the lubricant applied to the surface(s) thereof into a pre-heated forming tool so that the at least one surface contacts a surface of the forming tool. The method further involves, via the pre-heated forming tool, forming the sheet metal blank into a desired part shape, and during such forming, forming a lubricant layer on the surface(s) as the lubricant is heated from the pre-heated forming tool, the lubricant layer adhering to the surface(s) of the sheet metal blank.

Abstract: In one embodiment, a substrate, for example a tool used in hot metalforming operations, is coated with an enamel nanoparticulate graded coating. The nanoparticles in the coating may be boron nitride nanoparticles. The coating may include a first portion adjacent a surface of the substrate, and a second portion adjacent the first portion. The first portion of the coating may have a lower volume fraction of nanoparticles than the second portion. The first portion has excellent adhesion to the surface of the substrate, and the second portion reduces friction and wear. The coated tool may be formed by applying at least one layer of a coating mixture to a surface of the tool and heating the coating mixture. A metal workpiece may be formed into an article by contacting the metal workpiece against the coated surface of the tool.

Abstract: According to one embodiment, a film of solid lubricant particles is applied to metal workpieces, which are then subjected to a controlled humid environment for predetermined times and temperatures. Following the exposure to humidity, the lubricated metal workpieces are heated for a hot forming operation. The humidification of the lubricated workpiece increases the adhesion of solid lubricant films to the metal workpieces, thereby improving the tribological performance of the workpieces during subsequent hot forming operations.

Abstract: Corrosion resistant, manganese-stabilized austenitic stainless steels with a low nickel content are used in bipolar plates, methods for fabricating the bipolar plates, and polymer electrolyte membrane (PEM) fuel cells comprising the bipolar plates. The bipolar plates are formed from high-manganese austenitic stainless steels comprising, in weight percents, 4.0 to 35 manganese, 0.5 to 1.5 nickel, 17 to 20 chromium, 0.2 to 0.5 nitrogen, up to 0.075 carbon, 0.5 to 1.0 silicon, up to 0.1 aluminum, 0 to 0.005 sulfur, and balance iron and incidental impurities. The steels exhibit suitable corrosion resistance, electrical contact resistance, and mechanical properties for high-corrosion applications such as use in bipolar plate materials for PEM fuel cells. The bipolar plates may comprise a solid plate of the steel, optionally coated with a highly electrically conductive material.

Abstract: A metal forming process involves applying a lubricant, formed from a vitreous enamel mixed with particles of boron nitride, to at least one surface of a sheet metal blank, and without pre-heating the sheet metal blank, placing the sheet metal blank having the lubricant applied to the surface(s) thereof into a pre-heated forming tool so that the at least one surface contacts a surface of the forming tool. The method further involves, via the pre-heated forming tool, forming the sheet metal blank into a desired part shape, and during such forming, forming a lubricant layer on the surface(s) as the lubricant is heated from the pre-heated forming tool, the lubricant layer adhering to the surface(s) of the sheet metal blank.

Abstract: Corrosion resistant, manganese-stabilized austenitic stainless steels with a low nickel content are used in bipolar plates, methods for fabricating the bipolar plates, and polymer electrolyte membrane (PEM) fuel cells comprising the bipolar plates. The bipolar plates are formed from high-manganese austenitic stainless steels comprising, in weight percents, 4.0 to 35 manganese, 0.5 to 1.5 nickel, 17 to 20 chromium, 0.2 to 0.5 nitrogen, up to 0.075 carbon, 0.5 to 1.0 silicon, up to 0.1 aluminum, 0 to 0.005 sulfur, and balance iron and incidental impurities. The steels exhibit suitable corrosion resistance, electrical contact resistance, and mechanical properties for high-corrosion applications such as use in bipolar plate materials for PEM fuel cells. The bipolar plates may comprise a solid plate of the steel, optionally coated with a highly electrically conductive material.