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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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All sources NASA NTRS DOE OSTI

DOE OSTI2021

Thermomechanical fatigue resistance of low temperature solder for multiwire interconnects in photovoltaic modules

Novel interconnect technologies leveraging low melting temperature solders, such as multiwire interconnects, are being deployed in photovoltaic (PV) modules for improved reliability through interconnect redundancy and lower thermal loads during interconnection and lamination. However, the equivalency of standardized accelerated testing to field conditions has not yet been established for these emerging technologies. In this study, the thermomechanical fatigue resistance of low temperature solder alloys is investigated and compared to that of conventional SnPb to assess the acceleration behavior of these alloys. While InSn is shown to have sufficient thermomechanical fatigue resistance on the order of that of SnPb, these results indicate Sn–Bi alloys may have poor thermomechanical fatigue resistance at field conditions. The results also show that Sn–Bi alloys have thermal cycling acceleration factors of less than one. This indicates that the standardized accelerated thermal cycling test, such as that in IEC 61215, will produce misleading results for Sn–Bi alloys and that unique testing is required for this PV module architecture. Though accelerated thermal cycling may be a meaningful qualification test for SnPb solder joints, these results suggest that mechanical loading may be a more appropriate test for Sn–Bi multiwire interconnects. This is due to the distinct processing and geometry of multiwire interconnects which may allow for mechanical, rather than strictly metallurgical interconnections.

14 SOLAR ENERGY↗

DOE OSTI2014

Implications of Voyager 1 observations beyond the heliopause for the local interstellar electron spectrum

Cosmic-ray observations made by the Voyager 1 spacecraft outside the dominant modulating influence of the heliosphere finally allow the comparison of computed galactic spectra with experimental data at lower energies. These computed spectra, based on galactic propagation models, can now be compared with observations at low energies by Voyager 1 and at high energies by the PAMELA space detector at Earth. This improves understanding of basic propagation effects and also provides solar modulation studies with reliable input spectra from 1 MeV to 100 GeV. We set out to reproduce the Voyager 1 electron observations in the energy range of 6-60 MeV, as well as the PAMELA electron spectrum above 10 GeV, using the GALPROP code. By varying the source spectrum and galactic diffusion parameters, specifically the rigidity dependence of spatial diffusion, we find local interstellar spectra that agree with both power-law spectra observed by Voyager 1 beyond the heliopause. The local interstellar spectrum between ∼1 MeV and 100 GeV indicates that it is the combination of two power laws, with E {sup –(1.45} {sup ±} {sup 0.15)} below ∼100 MeV and E {sup –(3.15} {sup ±} {sup 0.05)} above ∼100 MeV. A gradual turn in the spectral shape matching the power laws is found, between 2.0 ± 0.5) GeV and (100 ± 10) MeV. According to our simplified modeling, this transition is caused primarily by galactic propagation effects. We find that the intensity beyond the heliopause at 10 MeV is (350 ± 50) electrons m{sup –2} s{sup –1} sr{sup –1} MeV{sup –1}, decreasing to (50 ± 5) electrons m{sup –2} s{sup –1} sr{sup –1} MeV{sup –1} at 100 MeV.

79 ASTRONOMY AND ASTROPHYSICS↗

DOE OSTI2024

Prioritizing circular economy strategies for sustainable PV deployment at the TW scale

Global decarbonization requires an unprecedented scale-up of photovoltaic (PV) manufacturing and deployment. The material demand and eventual end of life management associated with multi-TW scale deployment poses many challenges. Circular Economy (CE) and it's associated R-Actions (Reduce, Reuse, Recycle) have been proposed to mitigate end of life management and material sourcing concerns. However, CE metrics typically focus on a single product and only consider mass, excluding energy flows. This work leverages the PV in Circular Economy (PV ICE) tool to quantify the deployment, mass, and energy impacts of R-Actions and proposed sustainable PV designs in the context of achieving energy transition deployment goals (75 TW in 2050). 13 module scenarios are established and evaluated across 6 capacity, mass and energy metrics to identify tradeoffs and priorities. We find that increasing module efficiency can reduce near-term material demands up to 30% and improve energy metrics by up to 9%. Material circularity (recycling) can minimize lifecycle wastes and reduce material demands at the cost of higher energy demands. Increasing module lifetime, including reliability improvements and reuse strategies, is effective at reducing both material (>10%) and energy demands (24%). Uniquely, lifetime improvements maximize benefits and minimize the harms across all six metrics while achieving multi-TW scale deployment.

Photovoltaics↗

DOE OSTI2025

OPET Hardware (Open PV Electrical Tool Hardware) [SWR-25-42]

OPET (Open-source Photovoltaic Electrical Tool) is used for performance measurements of solar photovoltaic (PV) devices in the field under natural sunlight or in the lab under artificial light. Its primary use is in research and development of solar cells and modules, specifically in reliability and durability research of PV devices. Some features and functions include: -IV curve measurements with linear or cosine distributed measurement points -PV device active loading at open circuit voltage (Voc), short circuit current (Isc) and maximum power point (Pmp) -Bias power supply to overcome series resistance in contact wires for Isc measurements and loading -PV voltage input in five ranges from 1V to 100V -PV current input ranges -Low current version, six current ranges from 1.1mA to 340mA -High current version, six current ranges from 50mA to 15A -IO ports for I2C and SPI temperature sensor Arduino extension boards -Integrated fan control This repository contains everything relating to the hardware of the OPET device. If you are looking for the firmware or software repositories, links are below: https://github.com/NREL/opet-firmware https://github.com/NREL/opet-control

McDanold, Byron [National Renewable Energy Laborat↗

DOE OSTI2017

Development of ITM Oxygen Technology for Low-cost and Low-emission Gasification and Other Industrial Applications

Air Products carried out a scope of work under DOE Award No. DE-FE0012065 “Development of ITM Oxygen Technology for Low-cost and Low-emission Gasification and Other Industrial Applications” with subcontractors Ceramatec, Penn State, and WorleyParsons. The scope of work under this award was aimed at furthering the development of the Ion Transport Membrane (ITM) Oxygen production process toward a demonstration-scale facility known as the Oxygen Development Facility (ODF). Specific activities will help to enable design and construction of the ODF through advancement of a number of challenging technical elements that are required to manage risk in the initial deployment of ITM technology. Major objectives of the work included developing ITM Oxygen ceramic membrane materials with improved performance and reliability, optimizing ceramic module geometry and fabrication methods, testing module performance, trialing the improved fabrication process at commercial scale in the Ceramic Membrane Module Fabrication Facility (CerFab), and advancing engineering development of the ITM oxygen production process, including vessel design and contaminant control measures to prepare for deployment of the ODF. The comprehensive report that follows details the team’s work, which includes several notable accomplishments: 1) compressive creep, a likely limiter of ceramic module lifetime in service, was demonstrated to be retarded by an order of magnitude by changes in material formulation, module joining dimensions, and internal wafer geometry; 2) two promising new materials were shown to be superior to the incumbent ITM material in a key material parameter related to oxygen flux; 3) module degradation mechanisms were identified following operation in large pilot-scale equipment; 4) options for utilizing ITM in a coal-to-liquids (CTL) facility to enable liquids production with carbon capture were identified and studied; and 5) the benefits of potential improvements to the technology were assessed for their cost impact on ITM Oxygen applications to clean power, fuels, and other applications.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗

DOE OSTI2015

Development of ITM Oxygen Technology for Low-cost and Low-emission Gasification and Other Industrial Applications

42 ENGINEERING↗

DOE OSTI2019

Improvements to Bison Validation Base for LWR Fuel

The Bison fuel performance code is being developed by Idaho National Laboratory (INL) to analyze a wide range of fuel forms and operating conditions with the flexibility to conduct simulations in 1D through 3D geometries. Bison plays an important role in the development of advanced fuel with improved accident tolerance for existing light water reactors (LWRs), the improved understanding of mechanisms in fuel designs in a wider range of operating conditions, and the facilitation of future development of fuel for advanced reactor designs. Additionally, industry interest in advanced fuels has also driven Bison development for advanced fuels in the last few years. All of these factors combine to create a potential increase of new Bison users. These new users will potentially be interested in the Bison LWR validation base for examples of Bison's capabilities and how to use Bison. Current users also rely on the Bison validation base as a demonstration of the best practices settings and material behavioral models. Bison, both through direct updates to the Bison source code and to the nearly daily changes and improvements in the underlying MOOSE framework source code, undergoes nearly continuous changes. It is necessary that these source code changes are reflected with updated input files in the Bison validation base. Periodic updates of the validation case input files should also be accompanied by a review and revision of the validation case documentation on which our users rely. Therefore our efforts under this milestone were guided by two objectives: (1) Update the Bison LWR validation input files to use current Bison simulation settings, and (2) Enhance the ease-of-use for Bison through improved documentation These objectives build on the goals identified FY18 CASL milestone reports. During FY18 we addressed issues with the robustness of Bison and identified a need to migrate the assessment suite to the more reliable tensor mechanics module system and set a goal of standardizing the Bison input files. The FY18 CASL milestone report on updates to the Bison documentation system listed continued development of user-focused guides and examples along with revisions to the validation case documentation as future development goals. During FY19 we have separated these two objectives into four different focus areas for our work on this milestone. Our first two focus areas target the existing Bison validation suite: update the existing LWR validation cases and the accompanying documentation. The second two focus areas center on adding new capabilities: a new Bison LWR validation case and expansion of user support documentation. In the following report each of these four focus areas are discussed as a separate section. We conclude the report with a summary of potential future work to build on the efforts of this year.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2026

Optimizing Repowering and Lifecycle Decisions with PV ICE and SAM

Should you repower or extend the life of your PV system? Are high-efficiency modules, durable modules, or recyclable modules the best option for your site and goals? Evaluating the trade-offs in design and lifecycle strategies can be complex. The PV in Circular Economy (PV ICE) tool is an open-source model designed to help developers, modelers, and decision-makers assess material flows, energy return on investment (EROI), and financial viability of PV systems. Now integrated with the System Advisor Model (SAM), PV ICE enables site-specific comparisons of lifecycle strategies - such as repowering benefits, module selection for reliability and recyclability, among others. This interactive tutorial will provide hands-on experience with PV ICE using Google Collab, exploring scenario-based analyses on these topics.

36 MATERIALS SCIENCE↗

DOE OSTI2015

Round-Robin Verification and Final Development of the IEC 62788-1-5 Encapsulation Size Change Test; NREL (National Renewable Energy Laboratory)

Polymeric encapsulation materials may a change size when processed at typical module lamination temperatures. The relief of residual strain, trapped during the manufacture of encapsulation sheet, can affect module performance and reliability. For example, displaced cells and interconnects threaten: cell fracture; broken interconnects (open circuits and ground faults); delamination at interfaces; and void formation. A standardized test for the characterization of change in linear dimensions of encapsulation sheet has been developed and verified. The IEC 62788-1-5 standard quantifies the maximum change in linear dimensions that may occur to allow for process control of size change. Developments incorporated into the Committee Draft (CD) of the standard as well as the assessment of the repeatability and reproducibility of the test method are described here. No pass/fail criteria are given in the standard, rather a repeatable protocol to quantify the change in dimension is provided to aid those working with encapsulation. The round-robin experiment described here identified that the repeatability and reproducibility of measurements is on the order of 1%. Recent refinements to the test procedure to improve repeatability and reproducibility include: the use of a convection oven to improve the thermal equilibration time constant and its uniformity; well-defined measurement locations reduce the effects of sampling size -and location- relative to the specimen edges; a standardized sand substrate may be readily obtained to reduce friction that would otherwise complicate the results; specimen sampling is defined, so that material is examined at known sites across the width and length of rolls; and encapsulation should be examined at the manufacturer’s recommended processing temperature, except when a cross-linking reaction may limit the size change. EVA, for example, should be examined 100 °C, between its melt transition (occurring up to 80 °C) and the onset of cross-linking (often at 100 °C).

14 SOLAR ENERGY↗

DOE OSTI2018

Finite Element Simulation of Mixed-Mode PV Encapsulant Delamination Based on Cohesive Zone Model: Preprint

A finite element model (FEM) was developed to simulate the mixed-mode delamination failure at the encapsulant interface within PV modules under mixed-mode loading condi- tions. Parameters to characterize the bilinear traction-separation constitutive behavior of cohesive elements were determined by testing the pure mode I critical fracture energy of the photovotaic(PV) cell interface using the width-tapered beam and fitting the simulated load-displacement curve with the tested curve. This developed FEM can be used to predict the critical temperature changes, at which delamination would initiate, of PV modules with different sizes and provide guidance for the design of PV module with better reliability.

97 MATHEMATICS AND COMPUTING↗

DOE OSTI2024

Avancando na Transicao Energetica: Desafios e Estrategias para a Implantacao Sustentavel de FV

As the world embarks on an ambitious journey towards global decarbonization, the spotlight turns to photovoltaic (PV) technology as a cornerstone for sustainable energy solutions. This talk delves into the current status and projections of PV for the World, US and Brasil, and the necessary considerations to do this increase in manufacturing and deployment sustainably. With the projected scale of deployment, the industry faces significant challenges related to material demand and the management of PV modules at their end of life. The principles of the Circular Economy (CE) and its associated R-Actions - Reduce, Reuse, Recycle, among others - present a promising framework to address these challenges by mitigating end-of-life management and material sourcing concerns. However, traditional CE metrics, often focused solely on mass, fall short by excluding vital energy flow considerations. In this talk, we will highlight how various metrics are needed to understand sustainable PV solutions, how continuing the search for increased efficiency can significantly reduce material demands and enhance energy metrics, while strategies around material circularity and module lifetime and reliability improvements will offer substantial reductions in both material and energy demands.

Brasil↗

DOE OSTI2014

Moving to a Higher Level for PV Reliability through Comprehensive Standards Based on Solid Science (Presentation)

PV reliability is a challenging topic because of the desired long life of PV modules, the diversity of use environments and the pressure on companies to rapidly reduce their costs. This presentation describes the challenges, examples of failure mechanisms that we know or don't know how to test for, and how a scientific approach is being used to establish international standards.

14 SOLAR ENERGY↗

DOE OSTI2021

Characterization of front contact degradation in monocrystalline and multicrystalline silicon photovoltaic modules following damp heat exposure

Reliability and durability tests play a key role in the photovoltaic (PV) industry by minimizing potential failure risks for both existing and new cell and module technologies. In this work, a detailed study of contact degradation in monocrystalline and multicrystalline PV modules is performed. The modules are subjected to a sequence of damp heat (DH) exposures followed by electrical characterization after each step. Electroluminescence (EL) imaging shows different darkening patterns for monocrystalline modules compared to multicrystalline modules; the former shows darkening near the busbars and the latter shows it across virtually the entire cell surface. The primary loss mechanism is confirmed to be resistive after comparing the current-voltage (I–V) characteristics at each DH exposure step. Representative samples have been cored out from both the degraded modules and controls for materials characterization to gain further insights into the degradation mechanism. Top-down and cross-sectional scanning electron microscopy (SEM), energy dispersive spectroscopy (EDS), and top-down high-resolution X-ray photoelectron spectroscopy (XPS) analysis performed on the cored samples confirm the degradation is due to metallization corrosion. Our study suggests that the difference in the darkening pattern can most likely be attributed to the different silver paste composition used for contacting each cell technology, particularly the composition of the glass frit.

36 MATERIALS SCIENCE↗

DOE OSTI2014

Flexible Thin-Film Silicon Solar Cells

High fuel costs, environmental concerns and issues of national energy security have brought increasing attention to a distributed generation program for electricity based on solar technology. Rooftop photovoltaic (PV) systems provide distributed generation since the power is consumed at the point of production, thus eliminating the need for costly additional transmission lines. However, most current photovoltaic modules are heavy and require a significant amount of labor and accessory hardware such as mounting frames for installation on rooftops. This makes rooftop systems impractical or cost prohibitive in many instances. Under this project, Xunlight has advanced its manufacturing process for the production of lightweight, flexible thin-film silicon based photovoltaic modules, and has enhanced the reliability and performance of Xunlight’s products. These modules are easily unrolled and adhered directly to standard commercial roofs without mounting structures or integrated directly into roofing membrane materials for the lowest possible installation costs on the market. Importantly, Xunlight has now established strategic alliances with roofing material manufacturers and other OEMs for the development of building integrated photovoltaic roofing and other PV-enabled products, and has deployed its products in a number of commercial installations with these business partners.

14 SOLAR ENERGY↗

DOE OSTI2024

Contactless Production Testing of Silicon Solar Cells

Critical cost reductions in silicon solar cells are made by minimizing silver usage in their metal contacts. The reason why is both clear and unavoidable—silver is not only expensive, but also a potential limiting resource for scale-up (the PV industry alone used 10.3 % of the global silver supply in 2020 [1]). The result is solar cells with vanishing electrical contact area that are extremely difficult to test prior to module manufacture, when they must be sorted for quality to maximize power output and reliability of the subsequent modules. This project developed a new measurement instrument that enables the transition to solar cells with very low silver content, including cell designs with both minimal busbars and no busbars at all to electrically contact. The resulting instrument at project completion demonstrated the ability to sort cells with comparable—or better—results than existing technology. Compared to existing cell-test instruments, the new tool has minimal contacting requirements, which lowers the maintenance costs and use of consumable parts. We demonstrated innovative, yet pragmatic, solutions for reporting a comprehensive set of measurement results useful for both cell sorting (going forward in the line for module manufacture) and process control (looking backward in the line to identify cell manufacturing issues from wafer to cell-test). In addition to the traditional current-voltage characterization at cell test—short circuit current, open-circuit voltage, power, efficiency and fill factor—the new tool maintains all the advanced parameter characterization of our existing product line such as a substrate doping measurement, carrier recombination (lifetime) analysis, and surface recombination analysis.

14 SOLAR ENERGY↗

DOE OSTI2018

Reliable and Low Cost Monolayer Backsheet for cSi Solar Modules

The main purpose of this project was to develop a low cost single layer white and clear polymeric backsheet material for use in silicon PV modules. The cost savings to end users would be impactful, as the PV component market strives to reduce costs while continuing to meet increasingly stringent reliability requirements and disposal concerns.The importance of developing a white backsheet that is cost-effective, recyclable, and reliable is evident in the current market; moreover, the increased availability and use of bifacial cells is bound to increase the demand for transparent backsheets in future markets as well. Today, the cost of a clear backsheet is significantly higher than a white backsheet which provides additional motivation for research and development of new material options in the PV backsheet field.

14 SOLAR ENERGY↗

DOE OSTI2016

Chapter 9: Reliability

This chapter describes the accumulated knowledge on CPV reliability with its fundamentals and qualification. It explains the reliability of solar cells, modules (including optics) and plants. The chapter discusses the statistical distributions, namely exponential, normal and Weibull. The reliability of solar cells includes: namely the issues in accelerated aging tests in CPV solar cells, types of failure and failures in real time operation. The chapter explores the accelerated life tests, namely qualitative life tests (mainly HALT) and quantitative accelerated life tests (QALT). It examines other well proven and experienced PV cells and/or semiconductor devices, which share similar semiconductor materials, manufacturing techniques or operating conditions, namely, III-V space solar cells and light emitting diodes (LEDs). It addresses each of the identified reliability issues and presents the current state of the art knowledge for their testing and evaluation. Finally, the chapter summarizes the CPV qualification and reliability standards.

14 SOLAR ENERGY↗

DOE OSTI2025

Historical and Future Learning for the New Era of Multi-Terawatt Photovoltaics

Solar photovoltaics (PV) is entering a new era of multi-terawatt deployment, with 2 TW already in service and more than 75 TW predicted in many scenarios by 2050. This next era has been enabled by over five decades of cumulative advances in PV module cost reduction, performance and reliability. The current scale of deployment also introduces new needs, opportunities and challenges. In this Perspective we frame a path forwards based on learning, broadly defined as a combination of expansion of knowledge and advances through research and development, experience and collaboration. We discuss historical topics where learning has driven PV deployment until now, and emerging areas that are required to sustain high levels of future deployment. We expect progress to continue in terms of module price, performance and reliability, driven by advances in PV cell and module design, the emergence of tandem devices and increased focus on extending module lifetimes. Large-scale deployment also means large-scale sustainability and responsibility. We therefore posit that additional metrics, such as the impact on global CO2 emissions, resource consumption and design for reuse and recycling, will become increasingly important to the PV industry and provide opportunities for further learning.

14 SOLAR ENERGY↗