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All sources NASA NTRS DOE OSTI

DOE OSTI2025

Durability Research Is Pivotal for Perovskite Photovoltaics

Metal halide perovskite solar cells have shown promising power conversion efficiencies, but commercialization requires that decent durability is also demonstrated. Under normal operation, solar cells are subject to a complex combination of stressors, such as visible light, ultraviolet light, heat, humidity, mechanical stress and electric potential, which complicates the understanding of failure mechanisms. Existing stress tests do not act as a time machine. In new materials systems such as perovskite photovoltaics, the tests have no known relationship to field service. In this Perspective we recommend following a durability learning cycle that interleaves photovoltaic module engineering with field testing; accelerated testing; and preconditioning and performance engineering. We advocate for field testing to demonstrate real-world performance and identify field-relevant failure modes, and urge the community to develop accelerated and qualification tests that account for device metastability, variations in material composition and different/various processing methods. In conclusion, these practices are more difficult, but more important, than the simple pursuit of higher initial efficiencies.

14 SOLAR ENERGY↗

NASA NTRS1988

Fatique crack growth behavior of a single crystal alloy as observed through an in situ fatigue loading stage

An in situ fatigue loading stage inside a scanning electron microscope (SEM) was used to determine the fatigue crack growth behavior of a PWA 1480 single-crystal nickel-based superalloy. The loading stage permits real-time viewing of the fatigue damage processes at high magnification. The PWA 1480 single-crystal, single-edge notch specimens were tested with the load axis parallel to the (100) orientation. Two distinct fatigue failure mechanisms were identified. The crack growth rate differed substantially when the failure occurred on a single slip system in comparison to multislip system failure. Two processes by which crack branching is produced were identified and are discussed. Also discussed are the observed crack closure mechanisms.

Telesman, Jack↗

NASA NTRS1988

Fatigue crack growth behavior of a single crystal alloy as observed through an in situ fatigue loading stage

Telesman, Jack↗

NASA NTRS1985

Signal analysis techniques for incipient failure detection in turbomachinery

Signal analysis techniques for the detection and classification of incipient mechanical failures in turbomachinery were developed, implemented and evaluated. Signal analysis techniques available to describe dynamic measurement characteristics are reviewed. Time domain and spectral methods are described, and statistical classification in terms of moments is discussed. Several of these waveform analysis techniques were implemented on a computer and applied to dynamic signals. A laboratory evaluation of the methods with respect to signal detection capability is described. Plans for further technique evaluation and data base development to characterize turbopump incipient failure modes from Space Shuttle main engine (SSME) hot firing measurements are outlined.

Coffin, T.↗

DOE OSTI2024

In-situ determination of strain during transient burst testing and the temperature dependence of Zircaloy-4 claddings

Understanding fuel system behavior during postulated loss-of-coolant accidents is pertinent for continued safe and efficient operation of light water reactors, particularly as higher burnups are being pursued and safety margins re-evaluated. Conventional mechanical models for the incumbent Zr alloys typically rely on the assumption that steady-state creep is the dominant fuel cladding response during transient accident conditions. To investigate this assumption, simulated accident burst testing was performed on Zircaloy-4 claddings with balloon behavior measured in-situ. Here, two distinct loading conditions were utilized during burst testing: (1) constant-gas-inventory where pressure was allowed to increase with temperature and (2) constant pressure. In-situ strains and strain rates were measured via 2-dimensional digital image correlation techniques and synchronized with temperature to determine deformation dependencies. The temperature dependence of strain rate was characterized by a two segment Arrhenius relationship, with a distinct transition between the high and low temperature/strain regimes. The average activation energy of the lower temperature/strain regime was 328 ± 25 kJ/mol, in agreement with the ~320 kJ/mol used for conventional LOCA models. However, the higher temperature/strain segment, which encompassed most of ballooning, showed increased activation energies as well as a dependence on whether the burst region was in view. For tests that burst away from the camera view, the average high temperature/strain segment activation energy was 635 ± 150 kJ/mol. For samples where the rupture opening formed in view, the average activation energy was 1015 ± 179 kJ/mol. This observed shift in temperature dependence indicates a transition in deformation mechanism at the end of life, possibly to time independent failure mechanisms, which has not yet been visualized in the literature for Zr alloys. Parameters at the transition points were analyzed to determine thresholds for this change in behavior, which occurred at an average hoop strain of 6.9 ± 2.1 %.

36 MATERIALS SCIENCE↗

NASA NTRS1972

Adhesion theory review

Bonding theories reviewed include physical adsorption, hydrogen bonding, chemisorption and surface energy; bond failure mechanisms include phase discontinuity, swelling and corrosion. Concept of bond failure by water desorption is introduced and discussed.

Delollis, N. J.↗

NASA NTRS1985

Postbuckling of flat unstiffened graphite-epoxy plates loaded in shear

An experimental and analytical study was conducted of the postbuckling response and failure characteristics of 8-, 16-, and 24-ply unstiffened graphite/epoxy plates under shear loading, including orthotropic, quasi-orthotropic, entirely +, -45 deg ply, and (0/90)s-class plates. Postbuckling stiffness is noted to be influenced by the stacking sequence and by the inplane boundary condition imposed on the test section by a picture frame test fixture. The ratio of failure load to buckling load was higher for specimens that had higher width-to-thickness ratios. It is noted that high displacement gradients may induce transverse shear stresses, and that delamination was the failure mechanism for many of the 8-ply specimens. An adhesive failure between the composite specimen and metal edge reinforcements initiated failure of the 16- and 24-ply specimens.

Rouse, M.↗

NASA NTRS1996

A 100 Hour Wear Test of the NASA NSTAR Ion Thruster

In a NASA program to validate 30 cm Xenon ion thruster technology for use in planetary missions a combination of analysis and testing is being used to establish engine reliability. Five long duration tests are planned to identify new failure mechanisms and characterize the parameters which drive known damage accumulation failure modes.

ion thruster NSTAR xenon ion propulsion ion propul↗

NASA NTRS2012

Extended Testability Analysis Tool

The Extended Testability Analysis (ETA) Tool is a software application that supports fault management (FM) by performing testability analyses on the fault propagation model of a given system. Fault management includes the prevention of faults through robust design margins and quality assurance methods, or the mitigation of system failures. Fault management requires an understanding of the system design and operation, potential failure mechanisms within the system, and the propagation of those potential failures through the system. The purpose of the ETA Tool software is to process the testability analysis results from a commercial software program called TEAMS Designer in order to provide a detailed set of diagnostic assessment reports. The ETA Tool is a command-line process with several user-selectable report output options. The ETA Tool also extends the COTS testability analysis and enables variation studies with sensor sensitivity impacts on system diagnostics and component isolation using a single testability output. The ETA Tool can also provide extended analyses from a single set of testability output files. The following analysis reports are available to the user: (1) the Detectability Report provides a breakdown of how each tested failure mode was detected, (2) the Test Utilization Report identifies all the failure modes that each test detects, (3) the Failure Mode Isolation Report demonstrates the system s ability to discriminate between failure modes, (4) the Component Isolation Report demonstrates the system s ability to discriminate between failure modes relative to the components containing the failure modes, (5) the Sensor Sensor Sensitivity Analysis Report shows the diagnostic impact due to loss of sensor information, and (6) the Effect Mapping Report identifies failure modes that result in specified system-level effects.

Melcher, Kevin↗

NASA NTRSDate not supplied

Manufacturing Trials of Integrally Stiffened Composite Panels Using Automated Fiber Placement

Commercial aircraft structures are frequently manufactured from carbon-epoxy materials because of their weight and stiffness advantages compared to metallic materials. Wing cover panels are regularly manufactured using an automated fiber placement (AFP) process, but current design and manufacturing methodologies do not fully take advantage of the opportunities afforded by AFP. Design and manufacturing studies were undertaken at the NASA Langley Research Center at the Integrated Structural Assembly of Advanced Composites (ISAAC) facility to quantify manufacturing benefits and limitations associated with AFP to create structurally efficient integral stiffeners as an alternative to bonded or mechanically fastened stiffeners. This methodology could save weight and remove failure mechanisms by reducing the need for rivets and bonding materials since the stiffener plies are interleaved within the skin plies. The use of AFP with integral stiffeners can open the design space, but a fundamental, systematic evaluation of manufacturing limitations is necessary. Manufacturing trials are described herein, where considered manufacturing variables included stiffener location, stiffener course staggering, stiffener widths, stiffener intersections, and material thicknesses for both the skin and stiffener plies. The manufacturing process and lessons learned from each trial are described, including the most successful current design which contains staggered stiffeners, non-traditional laminate angles, and a combination of multiple material thicknesses within the same laminate.

Composite manufacturing↗

NASA NTRSDate not supplied

Manufacturing Trials of Integrally Stiffened Composite Panels Using Automated Fiber Placement

Automated Fiber Placement↗

NASA NTRSDate not supplied

Parallelized Carbon Oxidation and Surface Recession Model in Direct-Simulation Monte Carlo Code, SPARTA

Ablative thermal protection system (TPS) materials for spacecraft are composites that often consist of a carbon-based reinforcement and a polymeric matrix. During Earth re-entry, they endure high-temperature oxidation and surface recession. Oxidation is an important mechanism for ablation, sometimes leading to the weakening, spallation, or failure of the oxidized fibers at the surface and in the char layer. However, more details are required including accurate material properties of the fiber microstructure, whether the fibers recede homogenously or localized at pits, and the role of pyrolysis outgassing in order to evaluate the role oxidation plays in the degradation and failure mechanisms of these materials. In this work, we demonstrate a parallelizable oxidation-driven ablation model developed for detailed, large-scale simulations in the DSMC code SPARTA. We also develop robust algorithms which handle the conservation of the surface state after an ablation step. Finally, we verify our model for both simple and more complex chemistry as well as microstructures with reaction statistics, oxidation depth calculations, and detailed visualization of oxidation-induced material recession at the microscale.

V Arias↗

DOE OSTI2023

PV Module and System Reliability Research

While photovoltaic (PV) technologies have experienced widespread success and adoption, continued growth of these technologies - especially new PV technologies - requires ongoing improvements to their reliability and the testing procedures, data, and standards that underpin them. To better understand and address failure mechanisms of PV modules and systems, NREL conducts testing, models failures, analyzes performance data, helps to develop standards, and convenes expert stakeholders. This work is focused both on improving the performance of industry-dominant PV technologies and rapidly de-risking new PV technologies so they can be proven reliable without decades of field testing.

14 SOLAR ENERGY↗

NASA NTRS1973

Register of specialized sources for information on mechanics of structural failure

Specialized information sources that generate information relative to six problem areas in aerospace mechanics of structural failure are identified. Selection for inclusion was based upon information obtained from the individual knowledge and professional contacts of Martin Marietta Aerospace staff members and the information uncovered by the staff of technical reviewers. Activities listed perform basic or applied research related to the mechanics of structural failure and publish the results of such research. The purpose of the register is to present, in easy reference form, original sources for dependable information regarding failure modes and mechanisms of aerospace structures.

Carpenter, J. L., Jr.↗

DOE OSTI2022

Overcoming Degradation Pathways to Achieve Stable Blue Perovskite Light-Emitting Diodes

Mixed halide (Br/Cl) perovskite nanocrystals (NCs) that represent an advanced blue emitter commonly suffer from spectral instability and poor lifespan; notably, the lack of understanding of the failure mechanisms of these devices has restricted the future progress. Here, we determine that the degradation of CsPbBr x Cl 3– x NCs containing blue light-emitting diodes (LEDs) is due to the combination of two effects. Cl – drift among adjoining NCs under an electric field is found to induce a Cl-deficient material region in multiple NC layers, which dominates the unstable electroluminescence and causes fast degradation in the corresponding devices. In comparison, the monolayer NC devices that feature restricted anion drift pathways exhibit better operational stability; however, excess hole injection is demonstrated to induce irreversible chlorine loss in NCs. Such a process that largely arises from electrochemical oxidation of Cl – initiates a mild device failure in operation of tens of minutes. Through revealing these mechanisms, we modulate the devices’ construction and operational conditions to achieve a longer lifespan.

14 SOLAR ENERGY↗

DOE OSTI2023

Large deformation and brittle failure calculated using the dual-domain material point method

The dual domain material point (DDMP) method is explored as a candidate to be implemented in a general purpose code to perform simulations of materials with complex geometry that undergo large history-dependent deformation and failure. To test its candidacy, we study its mesh convergence, its sensitivity to mesh orientation, and its ability to handle softening and failure of a material. Simulations of large deformation and simulations of mechanical failure are performed using both DDMP and the material point method (MPM). When cell-crossing of material points is not an issue and when there are a sufficient number of material points in each computation cell, the numerical error decreases with the square of the cell size as expected for both MPM and DDMP. DDMP has reduced error compared with MPM when there are many instances of material points crossing cell boundaries due to the continuous nature of the modified gradient of the shape functions. Simulations of a specimen under tension are also performed where the background mesh is aligned and misaligned with the tension direction. MPM displays a significant mesh-dependent stress field, DDMP shows negligible mesh dependency. Despite a mesh orientation-dependent stress field from MPM, the critical tension and failure mode from both MPM and DDMP calculations have negligible mesh dependency when using a non-local failure model. If only the failure mode is important (i.e., local stresses are unimportant), MPM with a non-local failure model is a suitable method for modeling failure with small deformations. However, if local stresses are also important or if there are large deformations with many cell-crossings before failure, DDMP should be the method that is used. A needed improvement for DDMP is identified from our numerical simulations.

36 MATERIALS SCIENCE↗

DOE OSTI2023

The combined effect of temperature and seawater on the compression properties of carbon fiber vinyl ester composites for sandwich structures

For naval applications, composite sandwich structures are of significant interest, and are often manufactured using thin (2 to 4 mm) composite facings made from carbon or glass fiber reinforcement, attached to a thick (25 to 50 mm) section of PVC cellular foam or balsa wood-based core materials using a suitable polymeric resin. In the present study, we focus on the hygrothermal effect on the fiber-dominated compression properties of carbon fiber reinforced vinyl ester resin based polymeric composite (CF/VE), used as “skin” for a polymeric composite sandwich material. Hygrothermal conditioning is achieved by saturating samples in simulated seawater at 40°C. Compression properties are evaluated for coupons extracted along warp and fill undergoing- no conditioning, conditioning till saturation (up to 6 months), and long-term conditioning (2 years). Sea-water saturation yields in up to 12% drop in compression strength with a further 3–4% drop resulting from long-term conditioning. No statistically significant modulus degradation is noticed due to short or long-term hygrothermal exposure. The failure mechanism of the warp extracted coupon, which fails in a splitting failure mode originating due to the delamination between the 0/90 interface, or the fill extracted coupon, which fails due to the instability caused by tow micro-buckling, remains unchanged due to combined exposure (short or long-term) of seawater and temperature. The loss in strength is attributed to the degradation of the fiber-matrix interface, which is validated via conducting single fiber push-in tests with a nominal diameter of 7 micron for conditioned and unconditioned coupons.

Engineering↗

NASA NTRS1971

Metallization failures

Metallization-related failure mechanisms were shown to be a major cause of integrated circuit failures under accelerated stress conditions, as well as in actual use under field operation. The integrated circuit industry is aware of the problem and is attempting to solve it in one of two ways: (1) better understanding of the aluminum system, which is the most widely used metallization material for silicon integrated circuits both as a single level and multilevel metallization, or (2) evaluating alternative metal systems. Aluminum metallization offers many advantages, but also has limitations particularly at elevated temperatures and high current densities. As an alternative, multilayer systems of the general form, silicon device-metal-inorganic insulator-metal, are being considered to produce large scale integrated arrays. The merits and restrictions of metallization systems in current usage and systems under development are defined.

Beatty, R.↗