Fuel cell electric vehicles represent a possible solution to meet the objectives of the energy transition currently underway, which sees the replacement of combustion vehicles with low environmental impact vehicles. For this reason, this market is expected to markedly grow in the coming years. Currently, the most suitable fuel cell technology for both light and heavy transport applications is the Proton Exchange Membrane fuel cell. This review provides a comprehensive description of the state of the art of fuel cell electric vehicles at different levels: vehicle configuration, fuel cell stack, and all the necessary operation systems. The current advantages and limits of the mentioned technology are highlighted, referring to recent studies aimed at optimizing the efficiency of the system and providing future perspectives.

Due to their attractive properties, such as high energy and power density, Lithium-ion batteries are currently the most suitable energy storage system for powering portable electronic equipment, electric vehicles, etc. However, they are still affected by safety and stability problems that need to be solved to allow a wider range of applications, especially for critical areas such as power networks and aeronautics. In this paper, the issue of overdischarge abuse has been addressed on Lithium-ion cells with different anode materials: a graphite-based anode and a Lithium Titanate Oxide (LTO)-based anode model. Tests were carried out at different depths of discharge (DOD%) in order to determine the effect of DOD% on cell performance and the critical conditions that often make the cell fail irreversibly. Tests on graphite anode cells have shown that at DOD% higher than 110% the cell is damaged irreversibly; while at DOD% lower than 110% electrolyte deposits form on the anodic surface and structural damage affects the cathode during cycling after the overdischarge. Furthermore, at any DOD%, copper deposits are found on the anode. In contrast with the graphite anode, it was always possible to recharge the LTO-based anode cells and restore their operation, though in the case of DOD% of 140% a drastic reduction in the recovered capacity was observed. In no case was there any venting of the cell, or any explosive event.

Temperature control is one of the most significant factors to improve the performance and extend the cycle life of a battery. It is, therefore, important to design and implement an effective battery thermal management system (TMS). Phase change materials (PCMs) can be used as a cooling means for batteries. In the present paper, a preliminary analysis of the thermal behavior of PCMs used to cool down a heated metal surface was carried out. Tests have shown that pure PCMs are able to limit the temperature increase, but only for relatively low-heat fluxes. At higher values of the heat produced, the thermal conductivity of the PCM was increased by using solid foams characterized by higher thermal conductivity; it was, thus, possible to keep the surface temperature within safe limits for longer times. A computational fluid dynamics (CFD) model of the composite material (PCM + solid foam) was also developed, which allowed to predict the temperature trend within the system under different boundary conditions. However, the average thermal conductivity of the composite system that best fitted the experimental results was found to be much lower than that theoretically predicted by using common semiempirical correlations.

Lithium titanate oxide cells are gaining attention in electric vehicle applications due to their ability to support high-current charging and their enhanced thermal stability. However, despite these advantages, safety concerns, particularly thermal runaway, pose significant challenges during abuse conditions such as overcharging. In this study, we investigated the effectiveness of various dielectric fluids in mitigating thermal runaway during overcharge abuse tests of cylindrical LTO cells with a capacity of 10 Ah. The experimental campaign focused on overcharging fully charged cells (starting at 100% State of Charge) at a current of 40A (4C). The tests were conducted under two conditions: the first benchmark test involved a cell exposed to air, while the subsequent tests involved cells submerged in different dielectric fluids. These fluids included two perfluoropolyether fluorinated fluids (PFPEs) with boiling points of 170 °C and 270 °C, respectively, a synthetic ester, and a silicone oil. The results were analyzed to determine the fluids’ ability to delay possible thermal runaway and prevent catastrophic failures. The findings demonstrate that some dielectric fluids can delay thermal runaway, with one fluid showing superior performance with respect to the others in preventing fire during thermal runaway. The top-performing fluid was further evaluated in a simulated battery pack environment, confirming its ability to mitigate thermal runaway risks. These results provide important insights for improving the safety of battery systems in electric vehicles.

Phase change materials (PCMs) are an interesting solution to increase the efficiency of thermal energy storage (TES) systems. The present work explores, with an experimental and computational study, the behavior of a paraffin wax encapsulated in a spherical containment system during the melting and solidification phases. The experimental tests were conducted by immersing the spherical capsule in a thermostatic water bath at different temperatures and measuring the temperatures at four different points inside the capsule. A two-dimensional CFD model of the sphere was then applied to investigate the effect of the insertion of a solid foam into the sphere to increase the system’s responsiveness under demanding conditions. In addition, an analysis of the solidification process considering two different wall materials (HDPE and aluminum) with different thermal conductivity was performed. The results suggest that embedded foams can represent a useful tool to increase the efficiency of a PCM-based TES, but, at the same time, they also highlight that a considerable increase in thermal conductivity is required to achieve significant advantages with respect to pure PCM systems.