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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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At least 289 records · Page 16
All sourcesNASA NTRSDOE OSTI
DOE OSTI2018

Smart Matrix Development for Direct Carbonate Fuel Cell

FCE’s (FuelCell Energy, Inc.) SureSourceTM products based on high-temperature internal-reforming direct carbonate fuel cell (DFC®) technology are striving to meet growing worldwide demand for high-efficiency ultra-clean power for on-site electric and combined heat and power (CHP) generation. It promises ~20% higher energy conversion efficiency than existing technologies and its large-scale deployment would help to reduce GHG (Green House Gas) emission. In this program, FCE, teamed with University of Connecticut (UConn) and Illinois Institute of Technology (IIT), successfully developed an innovative electrolyte matrix (dubbed smart matrix since it promises higher power output, longer service life, and cost reduction gains concurrently) to enable the products to worldwide deployment. The electrolyte membrane (matrix) holds a very important key to fulfill these promises. The matrix, a porous microstructure consisting mainly of ultra-fine sub-micron α-LiAlO 2 powders sandwiched between two electrodes, immobilizes liquid electrolyte, isolates fuel from oxidant and facilitates ionic transport. However, faster coarsening of α-LiAlO 2 at the reducing anode side lowers capillary electrolyte-retention and eventually leads to matrix drying, limiting stack service life. This program, spanning over 3.5 years, successfully developed a high-yield cost-effective commercial-ready smart matrix with robust and stable fine-pore microstructure to enable the SureSource plants meeting DOE 2020 targets for CHP distributed generation fuel cell systems. Fundamental coarsening mechanism was established by investigating in detail the effects of electrolyte chemistry, powder morphology, powder purity, electrolyte chemistry, gas atmosphere and temperature. More stable powders with higher crystallinity, less surface disorder, less metastable impurities, less agglomeration and more uniform particle-size distribution have improved stability. FCE devised an innovative cost-effective additive approach to disrupt the fundamental coarsening process to enhance stability. The smart matrix design was validated in numerous long-term accelerated single cells and several 30kW technology stacks, many operated for >5,000 hours. Manufacturing process was successfully optimized to produce high-yield full-area (1 m 2 ) product-size smart matrices. Field deployment has been initiated. Successful development of this innovative smart matrix enables a quantum jump in useful life (100%) and power output (>20%). These improvements may project to >20% lower COE (Cost of Electricity) making the SureSource highly competitive with U.S. grid electricity cost leading to large-scale deployment, realizing the U.S. Government’s energy, environment, and economic agenda.

03 NATURAL GAS↗
DOE OSTI2016

GAIN Technology Workshops Summary Report

National and global demand for nuclear energy is increasing and United States (U.S.) global leadership is eroding. There is a sense of urgency with respect to the deployment of the innovative nuclear energy technologies. The Gateway for Accelerated Innovation in Nuclear (GAIN) initiative is based on the simultaneous achievement of three strategic goals. The first is maintaining global technology leadership within the U.S. Department of Energy (DOE). The second is enabling global industrial leadership for nuclear vendors and suppliers. The third is focused on utility optimization of nuclear energy within the clean energy portfolio. An effective public-private partnership is required to achieve these goals. DOEs recognizes the recent sense of urgency new developers and investors have in getting their concepts to market. They know that time to market for nuclear technology takes too long and the facilities needed to conduct the necessary research, development and demonstration (RD&D) activities are very expensive to develop and maintain. Early technologies, in the lower technology readiness levels (TRL) need materials testing, analysis, modeling, code development, etc., most of which currently exists in the DOE national laboratory system. However, mature technologies typically need large component testing and demonstration facilities, which are expensive and long-lead efforts. By understanding the needs of advanced nuclear technology developers, GAIN will connect DOE national laboratory capabilities (e.g., facilities, expertise, materials, and data) with industry RD&D needs. In addition, GAIN is working with the Nuclear Regulatory Commission (NRC) to streamline processes and increase understanding of the licensing requirements for advanced reactors.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2023

Non-linear Wire Rope Isolator Model to Enhance Transportation Simulation of Fragile Equipment

Abstract Introduction Wire rope isolators are often used as means of vibration isolation for the transportation of fragile machine equipment. When deployed as suspension systems in a transportation scenario, a simple spring–damper model is often used to predict the dynamic loads that act on the structure being transported. However, this simple model has proved to be too simplistic to be used in the development of an accurate numerical model that can predict the vibration levels experienced by the inner components of fragile equipment during its transportation. This paper describes the experimental tests conducted on a wire rope isolator used for the transportation of the prototype SSR1 cryomodule. Materials and methods A hysteretic Bouc–Wen model has been used to analytically describe the force–deformation relationship of the wire rope isolators. The developed model of the isolator has been implemented in a larger model to simulate the actual transportation of the prototype SSR1 cryomodule, a section of the new PIP-II linear accelerator under construction at Fermilab. A series of multibody dynamic simulations with rigid and flexible components was used to numerically determine the acceleration of some critical components. Results and conclusions An actual experimental transportation was simulated using two numerical models: the developed Bouc–Wen model and a conventional spring–damper model. It is shown how the Bouc–Wen formulation of the isolator characteristics drastically improves the correspondence between experimental and simulated results if compared to a spring–damper model, especially in the range of 0–30 Hz which is the most critical for transportation problems.

42 ENGINEERING↗
DOE OSTI2021

Recent progress in shattered pellet injection technology in support of the ITER disruption mitigation system*

Shattered pellet injection (SPI) has been selected as the baseline technology for the disruption mitigation (DM) system for ITER. Typical SPI utilizes cryogenic cooling to desublimate low pressure (<100 mbar) gases onto a cold zone within a pipe gun barrel, forming a cylindrical pellet. Pellets are dislodged from the barrel and accelerated using either a gas driven mechanical punch or high-pressure light-gas delivered by a fast-opening valve. SPI technology developed at Oak Ridge National Laboratory is currently deployed and operational on DIII-D, JET, and KSTAR. These SPI systems are used in experiments for physics scaling to ITER thermal mitigation and runaway electron dissipation/avoidance. The pellet sizes used for these machines are in the range of 4 to 12.5 mm in diameter with length to diameter ratios (L/D) of ~1.5. The current plan for ITER SPI is to utilize pellets that are 28.5 mm in diameter with an L/D of ~2. Furthermore, the large pellet sizes, high steady-state magnetic fields, and limitations of operating in a radiation environment render much of the current technology unusable. In addition to technology improvements, a deeper understanding of pellet material properties, formation, and release is being developed for implementation in future SPI designs, specifically ITER.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
NASA NTRS1969

Biosatellite II mission

Biosatellite B was launched from Cape Kennedy, Florida, on a two-stage DELTA launch vehicle at 6:04 p.m. on 7 September, 1967. Approximately nine minutes later the 435 kg spacecraft biological laboratory was placed into a satisfactory 315 km near-circular earth orbit, successfully separated from the launch vehicle's second stage and was designated Biosatellite II. The scientific payload consisting of thirteen selected general biology and radiation experiments were subjected to planned, carefully controlled environmental conditions during 45 hours of earth-orbital flight. The decision was made to abbreviate the scheduled 3-day mission by approximately one day because of a threatening tropical storm in the recovery area, and a problem of communication with the spacecraft from the tracking stations. Highest priority was placed on recovery which was essential to obtain the scientific results on all the experiments. The operational phase of the mission came to a successful conclusion with the deorbit of the recovery capsule, deployment of the parachute system and air recovery by the United States Air Force. The 127 kg recovery capsule was returned to biology laboratories at Hickam Air Force Base, Hawaii, for disassembly and immediate inspection and analysis of the biological materials by the experimenters. It was evident immediately that the quality of the biology was excellent and this fact gave promise of a high return of scientific data. The environmental conditions provided to the experimental material in the spacecraft, provisions for experimental controls, and operational considerations are presented as they relate to interpretation of the experimental results.

Biosatellite 2 Project↗
DOE OSTI2026

Thermal property characterization of phase change materials in building applications: A systematic review of fundamentals, recent progress, and future directions

Phase change materials (PCMs) can reduce building peak loads and enable demand-responsive thermal energy storage (TES), but their deployment depends on reliable measurement and interpretation of thermal properties across laboratory, intermediate, and application scales. Here, this review systematically examines characterization methods, testing protocols, and recent advances for neat PCMs and PCM composites, emphasizing thermal conductivity, enthalpy-related properties (phase change temperature, latent heat, specific heat), and cycling stability. For thermal conductivity, we compare steady-state and transient techniques and note limitations when phase transition and contact resistance affect measurements. For enthalpy–temperature characterization, we discuss differential scanning calorimetry together with intermediate- and bulk-scale methods, including T-history, heat flow meter testing, and three-layer calorimetry (3LC), to generate application-relevant enthalpy–temperature profiles. Cycling stability is organized into four experimental families: thermoelectric–air, fully thermoelectric, water-bath, and in situ chamber approaches, with attention to separating reversible supercooling from true degradation such as phase segregation. We highlight emerging noncontact diagnostics, including infrared thermography and embedded sensing, for spatially resolved validation and multiscale interpretation. Finally, we review the growing use of AI and machine learning for property prediction, inverse characterization from experimental signals, and real-time state estimation in building-integrated TES. Key needs include harmonized protocols, interlaboratory benchmarking, uncertainty reporting, and metadata-rich datasets to accelerate reproducible PCM qualification for grid-flexible buildings.

AI↗
DOE OSTI2021

NRIC Asset Suite Engineering and Operations Data Integration Plan

The National Reactor Innovation Center (NRIC), established by the U.S. Department of Energy (DOE) in August 2019, accelerates the demonstration and deployment of advanced nuclear energy through its mission to inspire stakeholders and the public, empower innovators, and deliver successful outcomes through efficient coordination of partners and resources. NRIC is a national program led by Idaho National Laboratory (INL), enabling collaborators to harness the world-class capabilities of the U.S. National Laboratory System. Committed to demonstrating advanced reactors by the end of 2025, NRIC is designed to bridge the gap between research, development, and the marketplace to help convert some of the Nation’s most promising advanced nuclear reactors into commercial applications by 2030. To meet these needs, NRIC is developing two reactor demonstration test beds at Idaho National Laboratory (INL), the Laboratory for Operation and Testing in the United States (LOTUS) and the Demonstration and Operation of Microreactor Experiments (DOME) test bed. Each test bed involves the modification of existing facilities at INL’s Materials and Fuels Complex (MFC). Retrofitting these facilities to accommodate novel reactors, as well as subsequent but similar NRIC projects, is a non-trivial engineering task and is expected to generate a significant amount of new and revised documentation. Leveraging digital engineering practices, this documentation will be managed in a purpose-built data management tool to facilitate origination, review, and approval while coordinating with the design contractor. The subsequent upload and review of documentation to INL’s existing document control system comprises a long and unnecessarily manual task. An opportunity exists to automate this upload process and save job-hours while continuing to adhere to INL/MFC document management procedures.

99 GENERAL AND MISCELLANEOUS↗
DOE OSTI2022

Ultra-fast and Thick Boriding of Geothermal Casing to Enhance Reliability

Harnessing the heat that is continuously generated underneath the Earth’s crust (geothermal) is a clean and renewable source of energy. Geothermal energy can be used to heat and cool buildings, including greenhouses, and to generate electrical power. Compared to other renewable energy sources such as solar and wind, geothermal energy is more reliable because it is available all the time and versatile in its many forms of application and deployment. Nonetheless, the deployment and extensive use of geothermal energy still lags behind other renewable sources due to some technical, but mainly economic challenges. Upfront costs of geothermal power well development are relatively high. Some of this high cost is attributed to the use of expensive construction materials to ensure adequate performance during operation. For example, Inconel 625, super duplex 2507, and titanium alloy materials are used in downhole casings, piping, and other components exposed to brine solution to withstand harsh operating environments (high temperature and corrosive environments). Relatively low-cost carbon steel can be used in many of these components in geothermal power plants; however, they are susceptible to excessive corrosion, thereby limiting their useful lifespan. Ultra-fast boriding (UFB) surface treatment of carbon steel may drastically increase its corrosion resistance thereby providing a cost-effective material solution in geothermal applications. Scientists at Argonne National Laboratory (ANL) recently developed a technique to accelerate the boriding process using a high-temperature electrochemical process to produce relatively thick boride layers on various metal and alloy materials in minutes rather than the several hours it takes through the typical pack boriding process; hence, the process is designated UFB. The process uses molten borax salt at 900– 1000°C in an electrochemical cell in which the material to be borided is the cathode and a graphite plate is the anode. Continuous and durable boride layers with thicknesses of 100–300 µm have been produced on a variety of metals and alloys in one hour. Such a surface layer can indeed be a cost-effective pathway to prevent corrosion of casing materials in contact with the chemically aggressive and corrosive geothermal brine fluids.

15 GEOTHERMAL ENERGY↗
DOE OSTI2018

Compliant and stretchable thermoelectric coils for energy harvesting in miniature flexible devices

With accelerating trends in miniaturization of semiconductor devices, techniques for energy harvesting become increasingly important, especially in wearable technologies and sensors for the internet of things. Although thermoelectric systems have many attractive attributes in this context, maintaining large temperature differences across the device terminals and achieving low–thermal impedance interfaces to the surrounding environment become increasingly difficult to achieve as the characteristic dimensions decrease. Here, we propose and demonstrate an architectural solution to this problem, where thin-film active materials integrate into compliant, open three-dimensional (3D) forms. This approach not only enables efficient thermal impedance matching but also multiplies the heat flow through the harvester, thereby increasing the efficiencies for power conversion. Interconnected arrays of 3D thermoelectric coils built using microscale ribbons of monocrystalline silicon as the active material demonstrate these concepts. Quantitative measurements and simulations establish the basic operating principles and the key design features. The results suggest a scalable strategy for deploying hard thermoelectric thin-film materials in harvesters that can integrate effectively with soft materials systems, including those of the human body.

42 ENGINEERING↗
DOE OSTI2023

Revealing the Mechanism Behind Sudden Capacity Loss in Lithium Metal Batteries

Rechargeable Li-metal batteries (LMBs) are attractive energy storage candidates for electric vehicles (EVs) because they offer higher energy density than batteries built with intercalation electrodes. However, one of the main barriers to the commercial deployment of LMBs has been their relatively short cycle life. Re-designing the electrolyte system shows promise in achieving acceptable cycle life, but even so, the resulting cells display a challenging end-of-life (EOL) behavior: a sudden capacity loss. Herein, we report a new method for analyzing voltage profiles during cycling to distinguish between the capacity loss originating from the loss of cathode capacity vs growth in cell resistance. Further, this analysis reveals that sudden capacity loss was preceded by acceleration in the rate of growth of cell resistance, and cycling of multiple cells showed that this phenomenon is sensitive to the initial quantity of electrolyte in the cells. In contrast, the cathode capacity degraded at a constant rate independent of the electrolyte quantity. Combining this evidence with post-analysis of harvested electrolyte and electrodes, we conclude that neither the loss of active lithium nor the loss of active cathode material was the primary source of sudden capacity loss; instead, consumption and decomposition of electrolyte causes the drastic capacity loss at EOL.

25 ENERGY STORAGE↗
DOE OSTI2013

Deployment of Alumina Forming Austenitic (AFA) Stainless Steel

The purpose of the project was to accelerate the deployment and further the development of a new family of heat-resistant alloys developed at ORNL: alumina-forming austenitic (AFA) stainless steels. Initial laboratory scale evaluation indicated that AFA alloys possess exceptional high-temperature oxidation resistance while retaining creep properties similar to other advanced austenitic stainless steels. The AFA steels therefore represent a low-cost alternative to Ni-base alloys and a high performance alternative to conventional advanced austenitic steels. Deployment of AFA steels into turbine and other energy-related applications can lead to improved efficiencies by achieving higher operating temperatures and/or improved durability and component lifetime at costs comparable to currently used alloys. The development and scale up of optimized AFA alloy compositions in both wrought and cast forms, including generation of a database of thermo-physical, mechanical, welding/joining, and high-temperature corrosion properties was needed to enable consideration and adoption of these new materials in applications ranging from turbines, heat exchangers, and fuel cells to boilers and chemical/petrochemical processing. The project consisted of four primary tasks: commercial demonstrations, property database development, alloy development and optimization and evaluation of as-cast properties.

Alumina Forming Ausenitic Steel↗
DOE OSTI2026

High-throughput computation of electric polarization in solids via Berry flux diagonalization

Electric polarization in the absence of an externally applied electric field is a key property of polar materials, but the standard interpolation-based ab initio approach to compute polarization differences within the modern theory of polarization presents challenges for automated high-throughput calculations. Berry flux diagonalization [J. Bonini et al., Phys. Rev. B 102, 045141 (2020)] has been proposed as an efficient and reliable alternative, though it has yet to be widely deployed. Here, we assess Berry flux diagonalization using ab initio calculations of a large set of materials, introducing and validating heuristics that ensure branch alignment with a minimal number of intermediate interpolated structures. Our automated implementation of Berry flux diagonalization succeeds in cases where prior interpolation-based workflows fail due to band-gap closures or branch ambiguities. Benchmarking with ab initio calculations of 176 candidate ferroelectrics, we demonstrate the efficacy of the approach on a broad range of insulating materials and obtain accurate effective polarization values with fewer interpolated structures than prior automated interpolation-based workflows. Our real-space heuristics that can predict gauge stability a priori from ionic displacements enable a general automated framework for reliable polarization calculations and efficient high-throughput screening of chemically and structurally diverse polar insulators. These results establish Berry flux diagonalization as a robust and efficient method to compute the effective polarization of solids and to accelerate the data-driven discovery of functional polar materials.

Poteshman, Abigail N. [University of Chicago, IL (↗
DOE OSTI2013

Analysis of advanced european nuclear fuel cycle scenarios including transmutation and economical estimates

In this work the transition from the existing Light Water Reactors (LWR) to the advanced reactors is analyzed, including Generation III+ reactors in a European framework. Four European fuel cycle scenarios involving transmutation options have been addressed. The first scenario (i.e., reference) is the current fleet using LWR technology and open fuel cycle. The second scenario assumes a full replacement of the initial fleet with Fast Reactors (FR) burning U-Pu MOX fuel. The third scenario is a modification of the second one introducing Minor Actinide (MA) transmutation in a fraction of the FR fleet. Finally, in the fourth scenario, the LWR fleet is replaced using FR with MOX fuel as well as Accelerator Driven Systems (ADS) for MA transmutation. All scenarios consider an intermediate period of GEN-III+ LWR deployment and they extend for a period of 200 years looking for equilibrium mass flows. The simulations were made using the TR-EVOL code, a tool for fuel cycle studies developed by CIEMAT. The results reveal that all scenarios are feasible according to nuclear resources demand (U and Pu). Concerning to no transmutation cases, the second scenario reduces considerably the Pu inventory in repositories compared to the reference scenario, although the MA inventory increases. The transmutation scenarios show that elimination of the LWR MA legacy requires on one hand a maximum of 33% fraction (i.e., a peak value of 26 FR units) of the FR fleet dedicated to transmutation (MA in MOX fuel, homogeneous transmutation). On the other hand a maximum number of ADS plants accounting for 5% of electricity generation are predicted in the fourth scenario (i.e., 35 ADS units). Regarding the economic analysis, the estimations show an increase of LCOE (Levelized cost of electricity) - averaged over the whole period - with respect to the reference scenario of 21% and 29% for FR and FR with transmutation scenarios respectively, and 34% for the fourth scenario. (authors)

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2022

On-the-fly autonomous control of neutron diffraction via physics-informed Bayesian active learning

We demonstrate the first live, autonomous control over neutron diffraction experiments by developing and deploying ANDiE: the autonomous neutron diffraction explorer. Neutron scattering is a unique and versatile characterization technique for probing the magnetic structure and behavior of materials. However, instruments at neutron scattering facilities in the world is limited, and instruments at such facilities are perennially oversubscribed. We demonstrate a significant reduction in experimental time required for neutron diffraction experiments by implementation of autonomous navigation of measurement parameter space through machine learning. Prior scientific knowledge and Bayesian active learning are used to dynamically steer the sequence of measurements. We show that ANDiE can experimentally determine the magnetic ordering transition of both MnO and Fe 1.09 Te all while providing a fivefold enhancement in measurement efficiency. Furthermore, in a hypothesis testing post-processing step, ANDiE can determine transition behavior from a set of possible physical models. ANDiE's active learning approach is broadly applicable to a variety of neutron-based experiments and can open the door for neutron scattering as a tool of accelerated materials discovery.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Task 12 PV Sustainability - Status of PV Module Recycling in Selected IEA PVPS Task 12 Countries

Photovoltaic (PV) deployment has accelerated in recent years compared to projections in the early 2010s. This means that PV end of life (EOL) waste streams will also increase at a higher pace than anticipated. To meet and optimise PV EOL management, appropriate regulatory and technological approaches must be implemented in the near term, ensuring that available options are adapted to the conditions of each country or region. This report aims to review the current regulatory and industrial landscape for selected countries belonging to the International Energy Agency's PV Power Systems technology collaboration programme, to assess status of PV EOL management, allow for comparison and cross-fertilization, and establish a foundation for future tracking of progress. Although volumes of EOL PV modules are still small, EOL PV is treated and recycled in a proper manner in the countries and regions that have EOL regulations in place. However, the current low volumes, limited available recycling technologies, logistics challenges, and undeveloped markets for recovered materials result in a high-cost, low-revenue scenario for PV module recycling globally. Nevertheless, the implementation of PV EOL regulations in more countries and R&D investment in PV recycling is expected to accelerate further improvements to meet future demand and to achieve high-value, low-cost recycling. We hope this report contributes to understanding the global status of PV recycling and to accelerating its development as a promising option for the proper EOL management of PV modules in the coming decades.

14 SOLAR ENERGY↗
DOE OSTI2025

Leveraging a Southern California Energy Innovation Cluster to Pilot and Validate Emerging Energy Technologies

The EPIC Pilot Program, led by the Los Angeles Cleantech Incubator (LACI), was designed to help early-stage clean technology startups accelerate technical validation, investment readiness, and market entry. The project focused on supporting startups in designing and deploying small-scale pilots with the guidance of EPIC Partners, a network of regional stakeholders in the Southern California energy ecosystem, including but not limited to: the Los Angeles Department of Water and Power (LADWP), the California Energy Commission (CEC), Los Angeles County Metropolitan Transportation Authority (LA Metro), and Edison International, among others. Through mentorship, funding, and site access for technology deployments, the program provided a structured pathway for startups to test and refine their technologies in real-world settings.

14 SOLAR ENERGY↗
DOE OSTI2016

Preliminary Insights on Potential Transitions to Closed Thorium-Based Fuel Cycles

Closed fuel cycles with comprehensive recycle strategies are often regarded as the logical and desired end-states of long-term nuclear energy strategies; such options offer potential improvements in terms of resource supply and sustainability, waste management, and potentially nuclear security. In the DOE-NE Fuel Cycle Option Campaign report, systems with closed recycle strategies (both uranium- and thorium-based) generally dominated strategies with less comprehensive recycle approaches across many performance metrics. That being said, developing momentum to transition from the current global implementation of once-through fuel cycles has proven challenging. Intermediate paths en route to closed fuel cycles have not been readily elucidated; this is especially true for thorium-based options. A comparatively extensive amount of work has been conducted on transitions to closed fuel cycles based on uranium and plutonium, generally based on an endpoint of sodium-cooled fast reactors (SFRs). In contrast, corresponding analyses for thorium-based options are limited. Early estimates, without the benefit of full-scale modeling, were performed in conjunction with the Molten Salt Fast Reactor (MSFR) design. There is some transition analysis work associated with the Japanese THORIMS-NES molten salt design, but the scope of this work was not directly comparable with the SFR-oriented analyses and considered the thorium fission reactors as an intermediate state en route to the global deployment of accelerator-driven systems. Others have considered thorium recently, but not in a closed-recycle context. To begin to resolve this gap, this paper describes a high-level analysis and initial perspectives on the topic of transitions to closed thorium-based cycles. The emphasis on this paper is not on the specific quantitative results that are described, although some of the overall takeaways from these trends may still be useful. Instead, this paper describes the need for such analyses to be conducted, describes the methodologies by which this can be accomplished, and reports an initial demonstration of these methodologies for a specific transition candidate scenario. (authors)

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2017

Evaluation and modeling of the potential effects of a module manufacturing anomaly

Photovoltaic lifetime predictions are in great demand, but are exceedingly difficult to achieve with uncertainties small enough to be useful. During the construction of photovoltaic modules, small unplanned variability in materials or processes can have profound effects on module durability. Thus, continual monitoring of production quality is needed. In the subject production run, module quality, as monitored by damp heat testing, revealed a subset of modules that were prone to higher degradation rates. An assessment of the potential long-term power loss and mitigation strategies was needed. To do this, modules were exposed to variable levels of humidity and temperature with periodic monitoring. The analysis takes into account the kinetics of the degradation and the spatially and temporally varying humidity content within the module during accelerated stress testing. This is an important aspect for extrapolating laboratory results to field exposure because moisture ingress is diffusion limited in most laboratory module tests but not limited in these fielded modules. This analysis predicted that although a solder flux induce degradation mechanism is significant in accelerated stress test, this is probably an artifact of a process with a very large acceleration factor that is not likely to be significant for deployed modules. The degradation mechanism affected a limited area around the tabbing helping to minimize the effect. Furthermore, three years after the system was commissioned, the fielded modules indeed show no significant power loss.

14 SOLAR ENERGY↗