Topology Design, Multi-Objective Optimization, and Dynamic Performance Evaluation of a PCM-Buffered SOFC-MGT Hybrid Powertrain for Heavy-Duty Trucks

Decarbonizing heavy-duty logistics requires powertrains that integrate novel topology design, degradation-aware optimization, and robust dynamic performance under real-world operational loads. While solid oxide fuel cells offer high efficiency, their application in transportation is hindered by thermal fatigue. This study proposes a novel hybrid powertrain topology integrating a metal-supported solid oxide fuel cell (SOFC), a micro gas turbine (MGT), and an aluminum–silicon phase change material (PCM) thermal buffer. A high-fidelity dynamic model is developed and coupled with a multi-objective optimization framework to size the PCM buffer and battery pack, balancing capital expenditure and system lifetime. Furthermore, a degradation-aware energy management strategy based on a thermal state-of-charge metric is introduced. Simulations over a 10 h dynamic drive cycle indicate that the optimal configuration (120 kg PCM, 80 kWh battery) extends the SOFC’s simulated remaining useful life to 38,400 h, a 2.5-fold improvement over unbuffered systems. Concurrently, the proposed energy management strategy reduces the MGT mechanical wear index by 98% compared to conventional load-following strategies. The system demonstrates robust performance across ambient temperatures from −20 °C to +45 °C and achieves a 22% reduction in projected capital expenditure compared to standard proton exchange membrane fuel cell powertrains. This topology offers a highly durable and economically viable pathway for next-generation zero-emission heavy-duty vehicles. This work addresses a critical gap in the literature: the lack of integrated thermal buffering and degradation-aware control strategies for high-temperature fuel cell systems in dynamic vehicular applications. By coupling a physical latent heat buffer with a novel Thermal-SOC-proportional Energy Management Strategy, the proposed architecture directly targets the primary degradation mechanisms that have historically impeded SOFC commercialization in heavy-duty transport.