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DOE OSTI2026

Lessons from the IEC Durability of Adhesion Accelerated Test Sequence

The IEC 62788-1-1 and IEC 63209-2 standards use aging sequences for durability of adhesion in photovoltaic (PV) modules, which may be evaluated using the single cantilever beam (SCB) test. Because the encapsulant forms critical interfaces with the front glass and solar cells, degradation at those interfaces under ultraviolet (UV) exposure, elevated temperature, and humidity can lead to interfacial delamination - compromising the long-term reliability. In this work, adhesion durability of UV-transmitting poly(ethylene-co-vinyl acetate) (EVA) encapsulant to glass and to silicon solar cells is evaluated after sequenced UV and damp heat aging (85C/85%RH). Laminates were prepared using StarPhire solar front glass with thin glass or PERC cells, and two EVA formulations with different concentrations of siloxane coupling agent. Adhesion was quantified by measuring critical debond energy using the SCB method. Both formulations exhibit similar qualitative trends, while different adhesion is observed at the periphery despite the use of low-shrink manufacturing. The results show that while glass/EVA adhesion remains stable or increases after UV exposure and shows only moderate changes after damp heat, the EVA/cell interface exhibits an irreversible loss of adhesion following UV and then damp heat exposure. Although glass/EVA interfaces generally exhibit lower debond energies, the EVA/cell interface is significantly more vulnerable to UV-driven degradation, identifying it as the dominant reliability risk location through early- and intermediate-module life. These results demonstrate that accelerated aging sequences can expose large, interface-specific losses in adhesion durability and underscore the importance of interface engineering for long-term PV module reliability.

14 SOLAR ENERGY↗

DOE OSTI2015

Enhanced long-term strength and durability of shotcrete with high-strength C{sub 12}A{sub 7} mineral-based accelerator

This study evaluated the performance of shotcrete using high strength C{sub 12}A{sub 7} mineral-based accelerator that has been developed to improve the durability and long-term strength. Rebound, compressive strength and flexural strength were tested in the field. Test result showed that existing C{sub 12}A{sub 7} mineral-based accelerator exhibits better early strength than the high-strength C{sub 12}A{sub 7} mineral-based accelerator until the early age, but high-strength C{sub 12}A{sub 7} mineral-based accelerator shows about 29% higher at the long-term age of 28 days. Microstructural analysis such as scanning electron microscope (SEM), X-ray diffraction (XRD) and nitrogen adsorption method was evaluated to analyze long-term strength development mechanism of high strength C{sub 12}A{sub 7} mineral-based accelerator. As analysis result, it had more dense structure due to the reaction product by adding material that used to enhanced strength. It had better resistance performance in chloride ion penetration, freezing–thawing and carbonation than shotcrete that used existing C{sub 12}A{sub 7} mineral-based accelerator.

36 MATERIALS SCIENCE↗

DOE OSTI2015

SU-E-J-29: Automatic Image Registration Performance of Three IGRT Systems for Prostate Radiotherapy

Purpose: To compare the performance of an automatic image registration algorithm on image sets collected on three commercial image guidance systems, and explore its relationship with imaging parameters such as dose and sharpness. Methods: Images of a CIRS Virtually Human Male Pelvis phantom (VHMP) were collected on the CBCT systems of Varian TrueBeam/OBI and Elekta Synergy/XVI linear accelerators, across a range of mAs settings; and MVCT on a Tomotherapy Hi-ART accelerator with a range of pitch. Using the 6D correlation ratio algorithm of XVI, each image was registered to a mask of the prostate volume with a 5 mm expansion. Registrations were repeated 100 times, with random initial offsets introduced to simulate daily matching. Residual registration errors were calculated by correcting for the initial phantom set-up error. Automatic registration was also repeated after reconstructing images with different sharpness filters. Results: All three systems showed good registration performance, with residual translations <0.5mm (1σ) for typical clinical dose and reconstruction settings. Residual rotational error had larger range, with 0.8°, 1.2° and 1.9° for 1σ in XVI, OBI and Tomotherapy respectively. The registration accuracy of XVI images showed a strong dependence on imaging dose, particularly below 4mGy. No evidence of reduced performance was observed at the lowest dose settings for OBI and Tomotherapy, but these were above 4mGy. Registration failures (maximum target registration error > 3.6 mm on the surface of a 30mm sphere) occurred in 5% to 10% of registrations. Changing the sharpness of image reconstruction had no significant effect on registration performance. Conclusions: Using the present automatic image registration algorithm, all IGRT systems tested provided satisfactory registrations for clinical use, within a normal range of acquisition settings.

60 APPLIED LIFE SCIENCES↗

DOE OSTI2019

Optimizing the TiO{sub 2} Content to Obtain the Highest Corrosion Resistance in Ir-Ru-Ta-Based Mixed Metal Oxide Coating in Oxygen Evolution Reaction Application

In this article, the role of TiO{sub 2} on deactivation and corrosion mechanism of a MMO coating was assessed in 1 M Na{sub 2}SO{sub 4} solution. The Ti/40IrO{sub 2} + 30RuO{sub 2} + (30 − x)Ta{sub 2}O{sub 5} + (x)TiO{sub 2} anodes were prepared by thermal decomposition method. Surface morphology and microstructure of the coatings were characterized by scanning electron microscopy, energy-dispersive spectroscopy and grazing incidence x-ray diffraction analysis. The electrochemical properties and corrosion behavior of these coatings were performed by accelerated lifetime test, investigation of active surface area (q*) and electrochemical impedance spectroscopy. The results showed that the uniform dissolution of the active surface layers was the main reason behind the anode deactivation. Furthermore, addition of titanium oxide up to 15% to the above-mentioned composition improved the performance of the anode and increased its working life up to 200 h.

36 MATERIALS SCIENCE↗

DOE OSTI2010

Catastrophic optical degradation of the output facet of high-power single-transverse-mode diode lasers. 2. Calculation of the spatial temperature distribution and threshold of the catastrophic optical degradation

The temperature distribution and the power threshold during the catastrophic optical degradation are calculated within the framework of the developed model of the COD of the output facet in high-power single-transverse-mode diode lasers. Comparison of the calculation results and the experiment show the model adequacy. The contribution of different physical mechanisms into the heating of the laser output facet is analysed. It is shown that the model under study can help to develop the method for predicting the laser lifetime by the accelerated ageing tests. (lasers)

71 CLASSICAL AND QUANTUM MECHANICS, GENERAL PHYSIC↗

DOE OSTI2012

Verification of dosimetric accuracy on the TrueBeam STx: Rounded leaf effect of the high definition MLC

Purpose: The dosimetric leaf gap (DLG) in the Varian Eclipse treatment planning system is determined during commissioning and is used to model the effect of the rounded leaf-end of the multileaf collimator (MLC). This parameter attempts to model the physical difference between the radiation and light field and account for inherent leakage between leaf tips. With the increased use of single fraction high dose treatments requiring larger monitor units comes an enhanced concern in the accuracy of leakage calculations, as it accounts for much of the patient dose. This study serves to verify the dosimetric accuracy of the algorithm used to model the rounded leaf effect for the TrueBeam STx, and describes a methodology for determining best-practice parameter values, given the novel capabilities of the linear accelerator such as flattening filter free (FFF) treatments and a high definition MLC (HDMLC). Methods: During commissioning, the nominal MLC position was verified and the DLG parameter was determined using MLC-defined field sizes and moving gap tests, as is common in clinical testing. Treatment plans were created, and the DLG was optimized to achieve less than 1% difference between measured and calculated dose. The DLG value found was tested on treatment plans for all energies (6 MV, 10 MV, 15 MV, 6 MV FFF, 10 MV FFF) and modalities (3D conventional, IMRT, conformal arc, VMAT) available on the TrueBeam STx. Results: The DLG parameter found during the initial MLC testing did not match the leaf gap modeling parameter that provided the most accurate dose delivery in clinical treatment plans. Using the physical leaf gap size as the DLG for the HDMLC can lead to 5% differences in measured and calculated doses. Conclusions: Separate optimization of the DLG parameter using end-to-end tests must be performed to ensure dosimetric accuracy in the modeling of the rounded leaf ends for the Eclipse treatment planning system. The difference in leaf gap modeling versus physical leaf gap dimensions is more pronounced in the more recent versions of Eclipse for both the HDMLC and the Millennium MLC. Once properly commissioned and tested using a methodology based on treatment plan verification, Eclipse is able to accurately model radiation dose delivered for SBRT treatments using the TrueBeam STx.

60 APPLIED LIFE SCIENCES↗

DOE OSTI2013

Analysis of breathing cracks using vibrations

The influence of half-ellipse-shaped fatigue cracks and machined through-thickness cuts on the impact response of cantilever beam samples were analysed using the Finite Element Method and compared to experimental data for different crack depths. The effect of sample width was analysed for geometries with fatigue cracks (aspect ratio a/c = 0.45) and through-thickness cuts (rectangular cracks). The differences between both types of damage were analysed numerically and experimentally. The effect of sample width was studied and it was found that the behaviour of the cantilever with a fatigue-crack approaches that of the saw cut sample when the fatigue crack reaches the edges of the test piece. Acceleration data were analysed using the Fast Fourier Transform algorithm and Power Density Spectra (PSD) were obtained. For fatigue-cracked samples, harmonics of the frequencies of natural modes of oscillation were found. Analytical modelling was done using a mass-spring-damper system for studying the bilinear behaviour of the stiffness element. Harmonics found were assigned to the breathing behaviour of the crack. The detection threshold using frequency shifts inspection was twice as high as using spectral analysis. This would allow crack detection at half of the fatigue life of the specimen.

42 ENGINEERING↗

DOE OSTI2010

Sustainable Energy Solutions Task 2.0: Wind Turbine Reliability and Maintainability Enhancement through System-wide Structure Health Monitoring and Modifications to Rotating Components

An evaluation of nondestructive structural health monitoring methods was completed with over 132 documents, 37 specifically about wind turbines, summarized into a technology matrix. This matrix lists the technology, what can be monitored with this technology, and gives a short summary of the key aspects of the technology and its application. Passive and active acoustic emission equipment from Physical Acoustics Corp. and Acellent Technologies have been evaluated and selected for use in experimental state loading and fatigue tests of composite wind turbine blade materials. Acoustic Emission (AE) and Active Ultrasonic Testing (AUT), were applied to composite coupons with both simulated and actual damage. The results found that, while composites are more complicated in nature, compared to metallic structures, an artificial neural network analysis could still be used to determine damage. For the AE system, the failure mode could be determined (i.e. fiber breakage, delamination, etc.). The Acellent system has been evaluated to work well with composite materials. A test-rig for reliability testing of the rotating components was constructed. The research on the types of bearings used in the wind turbines indicated that in most of the designs, the main bearings utilized to support the shaft are cylindrical roller bearings. The accelerated degradation testing of a population of bearings was performed. Vibration and acoustic emission data was collected and analyzed in order to identify a representative degradation signal for each bearing to identify the initiation of the degradation process in the bearings. Afterwards, the RMS of the vibration signal from degradation initiation up to the end of the useful life of the bearing was selected to predict the remaining useful life of the bearing. This step included fitting Autoregressive Moving Average (ARMA) models to the degradation signals and approximating the probability distribution function (PDF) of remaining useful life based on the results of Monte-Carlo simulation of the ARMA models. This step was performed for different percentages of the degradation signal of each bearing. The accuracy of the proposed approach then was assessed by comparing the actual life of the bearing and the estimated life of the bearing from the developed models. The results were impressive and indicated that the accuracy of the models improved as more data was utilized in developing the ARMA models (we get closer to the end of the life of the bearing).

17 WIND ENERGY↗

DOE OSTI2011

Degradation Mechanisms and Accelerated Testing in PEM Fuel Cells

The durability of PEM fuel cells is a major barrier to the commercialization of these systems for stationary and transportation power applications. Although there has been recent progress in improving durability, further improvements are needed to meet the commercialization targets. Past improvements have largely been made possible because of the fundamental understanding of the underlying degradation mechanisms. By investigating component and cell degradation modes; defining the fundamental degradation mechanisms of components and component interactions new materials can be designed to improve durability. Various factors have been shown to affect the useful life of PEM fuel cells. Other issues arise from component optimization. Operational conditions (such as impurities in either the fuel or oxidant stream), cell environment, temperature (including subfreezing exposure), pressure, current, voltage, etc.; or transient versus continuous operation, including start-up and shutdown procedures, represent other factors that can affect cell performance and durability.

COMMERCIALIZATION↗

DOE OSTI2023

Compilation of a Solar Mirror Materials Database and an Analysis of Natural and Accelerated Mirror Exposure and Degradation

The National Renewable Energy Laboratory (NREL) has been conducting exposure experiments on solar reflectors for over four decades. Thousands of mirror samples from over one hundred suppliers have been exposed to and monitored in a range of relevant environments. These test conditions include outdoor test settings and several controlled laboratory environments. These samples have been rigorously individually characterized using a series of reflectance measurements, visual inspections, and in some cases, in-depth composition analysis to identify degradation modes, reflectance losses, and other mirror properties integral to understanding the solar reflector's life cycle. Here, this paper compiles the decades of measurement data into a concise statistical analysis. It includes exposure and degradation data for numerous reflector types, including secondary-surface reflector permutations of polymer and glass superstrates with silver and aluminum reflectors as well as front-surface reflectors. The results herein are intended to analyze environmental stressors and degradation trends among various historical and state-of-the-art solar reflectors. It may be used to support solar reflector design, effective testing methodology, and inform manufacturing decisions moving forward. Presented are the results of the compiled database and an initial analysis for degradation rate modeling using full-spectrum and wavelength-dependent approaches. The database is a growing resource hosted on a live, publicly accessible website. In conjunction with the analysis presented here, it provides a valuable resource to the solar reflector manufacturing and testing industry.

14 SOLAR ENERGY↗

DOE OSTI2018

Biocomposite Fiber-Matrix Treatments that Enhance In-Service Performance Can Also Accelerate End-of-Life Fragmentation and Anaerobic Biodegradation to Methane

Biodegradable resins can enhance the environmental sustainability of wood-plastic composites (WPCs) by enabling methane (CH{sub 4}) recovery via anaerobic digestion (AD). An under appreciated step in biocomposite AD is the role of cracking and fragmentation due to moisture uptake by the wood fiber (WF) fraction. Here, we use batch microcosms to simulate AD at end-of-life and to assess the effects of fiber-matrix treatments used to retard in-service moisture uptake. The composites evaluated were injection molded poly(hydroxybutyrate-co-hydroxyvalerate) (PHBV) with WF (0, 20%) using two fiber-matrix compatibilization treatments: (1) hydrophobic silane treatment of the wood fiber and (2) grafting of hydrophilic maleic anhydride groups to the PHBV matrix. Both treatments accelerated rates of mass loss and CH{sub 4} production by a factor of 1.2–2.3 compared to neat PHBV. The fragmentation rate, as measured by mass loss, increased significantly for treated samples compared to untreated samples. A ranking of test samples from lowest to highest rates of mass loss gave the following sequence: neat PHBV ≈ maleated PHBV < PHBV plus untreated WF < maleated PHBV plus untreated WF < PHBV plus silane-treated WF. Compared to the untreated samples, maleic anhydride treatment increased the mass loss rate by 30%, and silane treatment increased the mass loss rate by 92%. Onset of cracking in silane-treated composites was observed at 2 weeks (using X-ray micro-computed tomography). At the same time, solid mass loss and CH{sub 4} production peaked, implicating cracking and physical disintegration as the rate-limiting step for accelerated anaerobic degradation. When modified to account for bioplastic matrix degradation, a previously derived moisture-induced damage model could predict the onset of composite fragmentation at end-of-life. These results are significant for design of bio-WPCs and demonstrate that treatments designed to improve in-service performance can also improve end-of-life options.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2015

SU-E-T-38: A Head to Head Comparison of Two Commercial Phantoms Used for SRS QA

Purpose: To compare and contrast two commercial SRS QA phantoms. Methods: Both phantoms were evaluated in terms of their ease of setup as well as the time required to switch inserts for different tests. They were both used to evaluate the coincidence of the radiation and laser isocenters of a linear accelerator. End-to-end dosimetric tests were also performed using both ion chambers and films along two planes through the center of the phantoms. Since one phantom allows for multiple ion chamber orientations, a test was also performed to determine the effect of having the chamber oriented along the radiation beam axis’. Results: Changing inserts took 2 minutes on average for one phantom compared to 5 minutes for the other. The laser/radiation isocenter coincidence as determined from each phantom showed a maximum difference of 0.2mm. Ion chamber results were within 0.5% of the expected values when the chamber was perpendicular to the beams but measured a 3% underdose when the chamber was along the beam direction. Gamma (2%,2mm) pass rates of corresponding films were within 1% between phantoms. Conclusion: The results of the corresponding tests run on both phantoms were comparable, showing that the phantoms were equivalent for the subset of SRS QA tests run here. However, the under dose observed when the chamber was parallel to the beam direction suggests that this configuration should be avoided.

60 APPLIED LIFE SCIENCES↗

DOE OSTI2011

Methods for Service Life Time Estimation of Aluminum Reflectors

In order to reduce electricity generation costs of concentrating solar power (CSP) technologies, new low-cost reflector materials are being developed. These materials need to withstand difficult outdoor conditions without a significant loss in specular reflectance. In this work, samples of enhanced anodized aluminum reflectors protected by a sol-gel coating exposed at different weathering siteshave been analyzed with an innovative specular reflectometer and accelerated aging tests have been carried out in order to estimate the service lifetime. A new accelerated aging procedure is proposed, which consists in combining abrasion and corrosion testing.

14 SOLAR ENERGY↗

DOE OSTI2025

FY25 Status Update on A709 Code Case Testing at ANL

This report provides an update on the status of the creep rupture testing on the precipitation-treated (PT) Alloy 709 samples fabricated from the first, the second and the third commercial heats, in support of the first, 100,000-hour Alloy 709 Code Case development under the American Society of Mechanical Engineers (ASME) Section III, Division 5 for high-temperature reactor construction. In Fiscal Year (FY) 25, no new tests were initiated, while 5 previously loaded tests were completed. This report presents an overview of the creep-rupture data gathered at Argonne National Laboratory (ANL) since FY21 that totaled 52 completed tests. Metallographic images showing crack morphologies in some representative samples ruptured in FY25 are also included. Key conclusions include: 1) the creep behavior of the three heats of Alloy 709 can be well described by the Larson-Miller relationship; 2) higher temperatures and larger stresses lead to shorter creep life and higher minimum creep rate; 3) Alloy 709 is overall very ductile under creep; 4) the crack morphologies near fracture surfaces are dependent on material’s grain size and test conditions.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

DOE OSTI2021

Battery Performance, Thermal, and Life Modeling for Southern California Edison (Cooperative Research and Development Final Report)

The objective of this project is to develop battery performance models, thermal models and life models for SCE to use in simulation and analysis of grid services involving energy storage. NREL will fit the models to three separate chemistries using test data provided by SCE. The dataset for each chemistry will include electrical, thermal and aging response to different temperatures and cycling conditions, measured under a variety of cell-level and module-level experiments described in SCE test protocol documents. Once tuned to a test dataset, the battery system model software will provide predictions of battery energy and power loss, and thus cycle and calendar life, for any energy storage grid service power profile of interest to SCE. The automated battery life modeling and simulation tool can also be applied to any other grid battery systems as long as necessary input data is available to accelerate battery model development and battery lifetime analysis.

25 ENERGY STORAGE↗

DOE OSTI2024

DuraMAT: Building a Consortium to Accelerate the Photovoltaic Module Reliability Learning Cycle

Durable and reliable photovoltaic (PV) modules are critical to enabling an efficient transition to sustainable energy generation. The rate at which new module designs and materials are developed and deployed currently outpaces the rate at which we can identify failure mechanisms and understand degradation rates. Increasing the service life of PV modules, and our ability to predict performance over time, requires more durable materials and designs, better durability testing, more extensive material characterization, robust modeling, and methods to cross-examine historical performance data to extract meaningful results. This is a multidisciplinary challenge that requires expertise from a broad range of fields and, therefore, benefits significantly from a collaborative approach. In this Perspective, we outline the approach taken by the Durable Module Materials Consortium (DuraMAT), present a few case studies where our approach was successful, and provide an outlook on where this approach might be applied as the PV technology landscape continues to rapidly evolve. Published by the American Physical Society 2024

14 SOLAR ENERGY↗

DOE OSTI2019

Surface Treatment of Powder-Bed Fusion Additive Manufactured Metals for Improved Fatigue Life

High-cycle fatigue (HCF) tests were conducted on samples fabricated by two powder-bed additive manufacturing techniques. Samples were tested with as-produced surfaces and after various non-contact surface improvement treatments. Ti-6Al-4V samples were made using both electron beam melting (EBM) and selective laser melting (SLM), while Inconel 625 was fabricated using SLM. Ti-6Al-4V was treated with a commercial chemically accelerated vibratory polishing process, with target material removal of approximately 200 µm from each surface for EBM samples and 100 µm for SLM samples. This technique led to increases in both the number of cycles before failure at a given loading condition and endurance limit (at 10{sup 7} cycles) compared to samples with as-produced surfaces. The results are interpreted as the reduction in elastic stress concentration factor associated with surface defects where fatigue cracks initiate. SLM 625 was treated with both an abrasive polishing method and laser surface remelting. Both methods led to improvements in surface roughness, but these did not lead to improvements in fatigue properties of SLM 625. For abrasive polished samples, the combination of improved measured surface roughness without fatigue property enhancement suggests that surface material is removed, but the roots of surface defects, where fatigue cracks initiate, were left intact. For laser treatment, the remelted surface layer retained a rapidly solidified microstructure that did not increase the number of cycles before crack initiation even though the surface was smoother compared to the surface prior to polishing.

36 MATERIALS SCIENCE↗

DOE OSTI2022

Simulation of sugar kelp ( Saccharina latissima ) breeding guided by practices to accelerate genetic gains

Abstract Though Saccharina japonica cultivation has been established for many decades in East Asian countries, the domestication process of sugar kelp (Saccharina latissima) in the Northeast United States is still at its infancy. In this study, by using data from our breeding experience, we will demonstrate how obstacles for accelerated genetic gain can be assessed using simulation approaches that inform resource allocation decisions. Thus far, we have used 140 wild sporophytes that were sampled in 2018 from the northern Gulf of Maine to southern New England. From these sporophytes, we sampled gametophytes and made and evaluated over 600 progeny sporophytes from crosses among the gametophytes in 2019 and 2020. The biphasic life cycle of kelp gives a great advantage in selective breeding as we can potentially select both on the sporophytes and gametophytes. However, several obstacles exist, such as the amount of time it takes to complete a breeding cycle, the number of gametophytes that can be maintained in the laboratory, and whether positive selection can be conducted on farm-tested sporophytes. Using the Gulf of Maine population characteristics for heritability and effective population size, we simulated a founder population of 1,000 individuals and evaluated the impact of overcoming these obstacles on rate of genetic gain. Our results showed that key factors to improve current genetic gain rely mainly on our ability to induce reproduction of the best farm-tested sporophytes, and to accelerate the clonal vegetative growth of released gametophytes so that enough gametophyte biomass is ready for making crosses by the next growing season. Overcoming these challenges could improve rates of genetic gain more than 2-fold. Future research should focus on conditions favorable for inducing spring reproduction, and on increasing the amount of gametophyte tissue available in time to make fall crosses in the same year.

59 BASIC BIOLOGICAL SCIENCES↗