Hydrogen Fuel Cell Vehicles (FCVs)

Fuel cell vehicles, like battery electric vehicles, produce zero tailpipe emissions. Unlike BEVs, however, which must be recharged via an external power source, FCVs use an onboard fuel cell to create electrical power through a chemical reaction based on hydrogen fuel. Vehicles using fuel cells as the primary source of motive power can also be hybridized with a high-voltage battery, to improve vehicle performance and better optimize the cost and robustness of the fuel cell system.

We are continuing to develop and demonstrate hydrogen fuel cell technology with our Focus FCV test fleet. The Focus FCV uses Ballard fuel cell technology, called HyWay1, and is one of the industry's first hybridized fuel cell vehicles, meaning it has a hybrid battery system as well as a fuel cell system. A test fleet of 30 of our FCVs is currently in operation in cities throughout North America and Europe. In 2005, we placed Focus FCVs in Orlando, Sacramento, Southeast Michigan and Vancouver. In 2006, four more FCVs were placed in Berlin and Aachen, Germany, and in 2008 an FFV was placed in Iceland. Before being placed with commercial test fleets, these vehicles underwent an extensive and accelerated testing protocol to ensure they could last three years and 36,000 miles without incident. While on the road, the vehicles are providing important information about the performance of hydrogen FCVs in a wide range of driving and climate conditions. The total fleet has thus far accumulated more than 1,000,000 miles of real-world, on-road operation. The knowledge gained from this fleet will feed directly into Ford's future fuel cell research. Based on the knowledge gained from the Focus test fleet, we have completed development and lab validation of our new fuel cell technology, called HyWay2/3. This new technology improves the robustness and freeze start capability of the fuel cell propulsion system.

Even with the advances we have made in hydrogen technology over the past 10 years, we still have many challenges to overcome before hydrogen FCVs can compete in the market with current vehicle technology. The cost and durability of the fuel cell system are the most significant challenges. These problems remain too significant to allow for commercialization of FCVs at this point, even with the incremental improvements in the current state-of-the-art fuel cell.

The largest fraction of the cost of a fuel cell system is the fuel cell stack. We are therefore pursuing fundamental research into ways to achieve a significant reduction in the cost of this component. These research and development efforts include work on fuel cell catalysts to reduce the precious metal loading of the electrodes and alternatives to replace expensive materials. Simultaneously, we are working to increase power density, in order to improve the utilization of expensive materials. The components surrounding the power generation system, such as the air compressor and hydrogen recirculation pump, are also responsible for a large fraction of the cost of the fuel cell system. These technologies are relatively mature, however, which makes it difficult to achieve significant cost reductions. Simplification of the fuel cell stack power generation system may thus provide the best opportunity to reduce the overall cost of a fuel cell system. Materials development is crucial to our ability to optimize fuel cell stack operating conditions and reduce system complexity.

We are also working to improve fuel cell durability and the robustness of fuel cell materials under real-world usage. To this end, we are conducting extensive research on materials characterization and design optimization to help achieve robustness targets. For example, we are developing advanced analytical tools and modeling capability, including molecular dynamics. These analysis and modeling tools will help us acquire the information we need to improve our understanding of performance degradation and failure modes. As part of this effort, Ford is reprioritizing its resources to concentrate on fundamental fuel cell technology research, rather than demonstration vehicles. The key focus for this research is to significantly reduce costs and improve durability, in order to enable commercialization.

Hydrogen storage onboard the vehicle is another critical challenge to the commercial viability of hydrogen FCVs. We recognize that compressed hydrogen storage, which is currently used in the demonstration vehicles, may not be sufficient to achieve commercialization goals. We are therefore pursuing research on materials-based onboard hydrogen storage technology, including complex hydride and novel hydrogen sorbent technologies, which show technical potential.

Producing and distributing hydrogen fuel is another important hurdle on the road to implementing hydrogen-powered FCVs. As there is no widespread hydrogen fueling system, new infrastructure must be designed and executed throughout the country.

Working alone, Ford will not be able to overcome all of the challenges hydrogen vehicles face. That is why Ford is collaborating with a wide range of partners on the development of hydrogen vehicles, fuels and fueling systems. These partners include:

• The Freedom CAR and Fuel Partnership: a partnership between Ford, General Motors, Chrysler, five energy providers and the U.S. Department of Energy to develop vehicles and fuels that will provide freedom from imported oil and carbon-based fuel emissions, and
• The Clean Energy Partnership; a consortium of 12 corporate partners and the German government that is working to demonstrate the suitability of hydrogen as a fuel for everyday use.