Hydrogen Catalyst Breakthrough Could Power Heavy-Duty Fuel-Cell Vehicles
Scientists at the U.S. Department of Energy’s Brookhaven National Laboratory have unveiled a new recipe for catalysts that could revolutionise hydrogen fuel-cell technology. Published in Nature Communications, the findings promise more durable, efficient fuel cells, a vital breakthrough for powering heavy-duty vehicles such as trucks and buses.
Hydrogen fuel cells have long been hailed as a clean alternative to diesel engines, generating electricity by combining hydrogen and oxygen with water as the only by-product. While they’re already gaining traction in passenger cars, scaling them for long-haul transport and freight remains a challenge. At the heart of this challenge lies the catalyst, the component that drives the chemical reaction inside the fuel cell.
Why heavy-duty vehicles need stronger catalysts
Kotaro Sasaki, a Brookhaven chemist leading the research alongside colleague Xueru Zhao, explained the critical role of catalysts: “Catalysts are the components that enable the chemistry at the electrodes inside a fuel cell. These materials, often made of metals, bring the reacting chemicals together and lower the energy required to run the reaction. But the catalyst has to be able to perform this function over and over in challenging conditions, such as high heat or a harsh acidic environment. Our study focused on designing a catalyst that can sustain high performance in these challenging conditions.”
Unlike passenger cars, heavy-duty vehicles demand significantly higher power outputs and durability. Their fuel cells must withstand extreme operating environments, endure high temperatures, and deliver consistently across thousands of miles of road use. Traditional catalysts struggle to maintain performance under these conditions, slowing down the commercialisation of fuel-cell trucks and buses.
The high-entropy solution
The Brookhaven team’s breakthrough lies in creating a nitrogen-doped catalyst built from a carefully tuned mix of five metals: platinum, cobalt, nickel, iron, and copper. This combination forms what’s known as a high-entropy intermetallic material. Unlike conventional alloys, these structures contain multiple elements arranged in an ordered atomic framework, giving them unusual stability and resilience.
Using advanced imaging at Brookhaven’s National Synchrotron Light Source II (NSLS-II) and the Condensed Matter Physics and Materials Science Department, the scientists revealed fascinating details. At the atomic level, the catalyst exhibited tiny distortions known as “sub-angstrom strain,” shifts in atomic positions smaller than the width of a single atom. Coupled with robust bonds between nitrogen atoms and metals, this unique structure delivered both heightened activity and exceptional durability.
Performance that shatters benchmarks
To prove its worth, the catalyst was put through punishing tests that mimicked the demands of heavy-duty transport. Over 90,000 operating cycles — roughly 25,000 hours of continuous use — the material maintained performance levels well above Department of Energy (DOE) targets. For context, this would equate to years of heavy truck operation without a significant drop in efficiency.
Zhao emphasised the significance of the results: “These results show a practical pathway to building fuel-cell systems that can power the trucks and buses of tomorrow. Our catalyst not only meets immediate market needs but also lays the groundwork for widespread adoption in heavy-duty transportation.”
Collaboration across disciplines
This achievement was made possible by a broad collaboration across Brookhaven’s research divisions. Specialists in surface electrochemistry synthesised and tested the catalyst, while the Condensed Matter Physics and Materials Science Department and the Center for Functional Nanomaterials (CFN) carried out in-depth structural analysis. At NSLS-II, one of the world’s most advanced light sources, researchers used Quick X-ray Absorption and Scattering (QAS) and In situ and Operando Soft X-ray Spectroscopy (IOS) beamlines to explore the atomic-scale mechanisms at work.
Zhao highlighted the value of this collaborative model: “This is a clear example of how fundamental research at a national laboratory can have real-world impact. By uncovering the atomic-scale mechanisms that make this catalyst so effective, we’re opening the door to practical technologies that meet industry needs.”
Funding and support
The project was funded by the U.S. Department of Energy. Both CFN and NSLS-II operate as DOE Office of Science user facilities at Brookhaven. As the largest single supporter of basic physical sciences research in the United States, the Office of Science is investing heavily in technologies that address urgent energy and climate challenges.
Hydrogen fuel cells: a growing global market
The implications of Brookhaven’s breakthrough stretch far beyond U.S. borders. According to the Hydrogen Council, global investment in hydrogen projects could exceed $500 billion by 2030, with heavy-duty vehicles representing a key growth sector. Hydrogen-powered buses are already hitting the roads in European cities, while Japan and South Korea are aggressively pursuing hydrogen truck programmes to decarbonise logistics.
Fuel cells are particularly well-suited for long-haul transport where battery-electric solutions face limitations. Compared to batteries, hydrogen systems offer faster refuelling, longer ranges, and lighter weight, all of which are essential for freight and public transport applications. The development of robust catalysts could tip the balance in favour of hydrogen adoption worldwide.
Industry response and future prospects
While Brookhaven’s findings are still in the research stage, industry players are watching closely. Major truck manufacturers such as Daimler, Volvo, and Toyota have all announced hydrogen fuel-cell projects, with pilot fleets already being tested on European and Asian roads. The U.S. Inflation Reduction Act and similar legislation abroad provide subsidies and infrastructure investment to accelerate hydrogen deployment.
Brookhaven’s breakthrough aligns neatly with these global efforts, offering the missing piece of the puzzle: catalysts tough enough to withstand years of heavy-duty use. If commercialised, this innovation could become a cornerstone of sustainable transport solutions.
Paving the way for cleaner roads
As nations push to slash carbon emissions from the transport sector, hydrogen fuel-cell vehicles are gaining momentum. Brookhaven’s catalyst discovery represents not just a scientific milestone but a practical advance towards greener, more resilient logistics networks. With further development, hydrogen-powered fleets could soon become an everyday reality, powering everything from city buses to cross-country freight.
The road ahead is clear: investing in resilient hydrogen technologies is no longer optional, it’s essential for meeting climate and energy goals.
