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All sourcesNASA NTRSDOE OSTI
NASA NTRSDate not supplied

Response of Ablative Thermal Protection Materials to Degradation in Low Earth Orbit –Characterization of Specimens from MISSE-13

The environment of low Earth orbit presents unique material interactions due to the presence of atomic oxygen and solar spectrum UV. A variety of degradation mechanisms can occur depending, inlarge part, on the specific material system involved. This talk will review the characterization of two ablative materials, PICA-D and HEEET, as well as relevant adhesive joints and coatings. PICA-D is a variant of the phenolic impregnated carbon ablator (PICA) and is the baseline thermal protection system (TPS) on Dragonfly and the lander for Mars Sample Return (MSR). HEEET is a 3D woven system from which MSR’s Earth entry TPS is derived. The samples for these materials were flown in orbit during the Materials International Space Station Experiment-13 (MISSE-13) which launched on March 6, 2020 and returned to Earth on January 13, 2021. Changes to surface microstructure and reflectivity will be presented along with tomographic analysis. The effect of differential erosion rates on the composites and the impacts of the orbit environment on coating performances will be discussed in the context of TPS performance and mission design aspects.

MISSE↗
NASA NTRSDate not supplied

Response of Ablative Thermal Protection Materials to Degradation in Low Earth Orbit – Characterization of Specimens from MISSE-13

The environment of low Earth orbit presents unique material interactions due to the presence of atomic oxygen and solar spectrum UV. A variety of degradation mechanisms can occur depending, in large part, on the specific material system involved. This talk will review the characterization of two ablative materials, PICA-D and HEEET, as well as relevant adhesive joints and coatings. PICA-D is a variant of the phenolic impregnated carbon ablator (PICA) and is the baseline thermal protection system (TPS) on Dragonfly and the lander for Mars Sample Return (MSR). HEEET is a 3D woven system from which MSR’s Earth entry TPS is derived. The samples for these materials were flown in orbit during the Materials International Space Station Experiment-13 (MISSE-13) which launched on March 6, 2020 and returned to Earth on January 13, 2021. Changes to surface microstructure and reflectivity will be presented along with tomographic analysis. The effect of differential erosion rates on the composites and the impacts of the orbit environment on coating performances will be discussed in the context of TPS performance and mission design aspects.

MISSE↗
NASA NTRS2023

Establishing Standardized Test Methods for Evaluating Space Suit Gloves

The Artemis space suit glove environmental protection garment (EPG) will be the first line of protection used to protect the crewmember’s hands from the environments encountered during extravehicular activity (EVA). As the Artemis missions will include more extreme environments, it is necessary to define tests to evaluate if gloves can meet new, challenging requirements. The NASA Engineering and Safety Center (NESC)has funded an effort with the goal to help vendors to produce a space suit glove that is sufficiently durable to meet the needs of the Artemis missions. Three problems were identified in meeting that goal. First, there are no standardized tests defined to evaluate the durability of space suit gloves for the extreme lunar environments. Second, there is insufficient data on glove performance in a lunar environment from which to compare new designs. And third, current ISS glove TMG fabrics are unlikely to be sufficient to meet Lunar requirements. Four tasks were established to answer different aspects of these three problems. Task 1 focused on the characterization of potential glove fabrics using ASTM standardized test methods when possible. When one did not exist, new standardized test procedures were devised. Task 2 focused on developing a procedure for characterizing the thermal performance of a glove assembly. Task 3 focused on devising a standard procedure for characterizing the dust/abrasion resistance of a space suit glove. Task 4 focused on devising a standard procedure for characterizing the cut resistance of a space suit glove while at cryogenic temperatures. The new procedures created in Tasks 2, 3 and 4 were then validated by testing the Phase VI glove to collect baseline data. This paper will summarize the approach used to establish standardized test methods for each task and will expound on the ASTM process to publish the new standards.

spacesuit↗
NASA NTRSDate not supplied

Rapid Cycle Amine 4.0 System Development

Carbon dioxide (CO2) and humidity control is a key function of the spacesuit Portable Life Support Subsystem (PLSS). The latest spacesuit design utilizes a pressure swing bed containing a solid amine sorbent to scrub CO2 and humidity produced by the crewmember from the ventilation loop. The solid amine sorbent removes CO2 and humidity from the ventilation loop through a chemisorption mechanism. Simultaneously, CO2 and humidity are desorbed to vacuum via the two-bed pressure swing system during operation. This continuous regeneration allows for longer Extravehicular Activity (EVA) times while minimizing maintenance, consumables, and power usage. This concept has been in development for over 20 years, during which many prototypes and design iterations have been fabricated and evaluated. This paper discusses the recent Rapid Cycle Amine (RCA) design, development, and testing that has been done to advance the technology. The most recent fabrication is the RCA 3.0. It was delivered to NASA Johnson Space Center in 2015 and has since been tested at the component level and at the integrated PLSS level. The purpose of the component level testing was to understand CO2 removal capacity, end-of-life performance, and establish a baseline performance prior to integrated testing. The RCA 3.0 was integrated into the Exploration Extravehicular Mobility Unit (xEMU) PLSS for a comprehensive Design Verification Test (DVT) series. The integrated testing provided the benefit of characterizing the impact performance degradation has on the system. Many of the RCA requirements were developed through analysis, based on the limitations of the PLSS and, in some cases, assumptions about the system and flow behavior. Integrated testing was an opportunity to validate those requirements and assumptions. While the RCA 3.0 was being tested, the next design iteration, RCA 4.0, was under development. The RCA 4.0 preliminary design phase began in late-2019 and shortly after the Preliminary Design Review, the critical design phase began in 2021. The design work has concluded with the completion of a Pre-Manufacturing Review in 2022. This paper provides an overview of the RCA 4.0 system design, summarizes the results of integrated RCA 3.0 testing, and discusses the pertinence of driving requirements such as mass, volume, and power consumption.

Kelsey Bloom↗
DOE OSTI2025

The Dynamic Networks Experiments: Virtual Experiments to Quantify Gains in Nuclear Explosion Monitoring

We describe an ongoing series of virtual experiments conducted collaboratively by four United States National Laboratories: Sandia National Laboratories, Los Alamos National Laboratory, Lawrence Livermore National Laboratory, and Pacific Northwest National Laboratory. These Dynamic Network Experiments (DNEs) provide an experimental framework to evaluate the potential impact of new research tools on nuclear explosion monitoring. The second DNE (DNE2), completed in 2024, exploited waveform data (seismic, infrasound, and electromagnetic) that was recorded by multi-modal sensors within and near the Nevada National Security Site and synthetic radionuclide signatures over multiple time periods. During the execution of DNE2, we processed and analyzed data through a multi-stage event processing pipeline that ingested raw data, performed quality control, detected signals, built events from these signals, located these events, and characterized the events’ source types and sizes. For each stage and over the entire event processing pipeline, we evaluated performance changes by comparing the performance of new data processing methods, models, and algorithms against a baseline. We also performed an additional execution phase to assess event processing pipeline function, speed, and efficiency against that of an expert analyst, including computational and manual efforts. Finally, we assessed the impact and effort of modern computing infrastructure on the monitoring pipeline. This paper describes key elements of the DNEs, from formulation through execution, as demonstrated in DNE2. The DNEs introduce several novel concepts to quantitatively measure the potential impact of new methods on explosion monitoring, including the collaborative design of multi-modal datasets, performance and logistical metrics, and integrated analyses.

42 ENGINEERING↗
DOE OSTI2024

Robust Combined Heat and Hybrid Power (CHHP) for High Electrical Efficiency Cogeneration

Georgia Tech (Prime Recipient), the University of Texas at El Paso (UTEP) and the National Energy Technology Laboratory (NETL) investigated a hybrid fuel cell/ gas turbine system concept as a combined heat and hybrid power (CHHP) system for both robust and high power-to-process heat ratio cogeneration. The novelty of the proposed system entailed the distinct, elevated electrical efficiencies it maintains while simultaneously supporting a broad span of heating needs (e.g., supply temperatures) demanded across variable heat loads. The scope included: 1) leveraging a pioneering national lab facility configured for dynamic system operability development of hybrid fuel cell/gas turbine cycles; 2) enabling technology development to adjust and modulate the quality and quantity of thermal supply to bottoming heat loads via novel extreme temperature gas bypass valves. Hybrid fuel cell/gas turbine systems have primarily been reduced-to-practice in a constrained (e.g., initial proof-of-concept) manner and have still demonstrated considerable electrical efficiencies. However, these pre-pilot systems have focused upon electrical efficiencies and electrical power generation as the exclusive energy demand. Such hybrid systems had not been extensively researched or developed for flexible and variable operation consisting of both power and heat demands; however, these variable combined power and heat demands are characteristic of many types of manufacturers such as animal/poultry processing, bakeries and milk/flour/pastry manufacturing, textile mills, and electrochemical processing. Commercially, developing the system into a working combined heat and power system benefits these types of manufacturers by allowing them to meet their power and heat demands at a lower cost, higher efficiency, and/or through onsite generation. Therefore, the technical scope of this project was largely to study and facilitate these hybrid systems as combined heat and hybrid power (CHHP) systems that include dynamic operability for variable heat and power loads and/or grid dynamics for various types of manufacturers. Simulation results were used to predict the performance of the CHHP system and conceptually develop it to achieve desired dynamic operability. Experimentally, the primary goal was to design, manufacture, and experiment upon a high-temperature bypass valve. Experimental data included air mass flow rates through the valve orifice when the valve was changed to variable extent between fully closed and fully open. The experimental data was then used to create a semi-empirical computational model of the bypass valve. Concluded simulation goals for the research included developing computational heat exchanger models for the hybrid system inclusive of the bottoming heat exchanger and the recuperative heat exchanger, and then combining the computational recuperator model with the computational valve model. Afterwards, the computational models were then integrated to predict the dynamic operation of hybrid fuel cell/gas turbine cycles throughout a design space and reporting such. The scope stated in the preceding paragraph was packaged into five specific goals: 1) enabling the simulation of dynamic combined heat and power through the creation of computational, modular heat exchanger models; 2) simulation and exploration of the CHHP system’s performance by integrating the heat exchanger models with the national lab’s pre-existing hybrid system (computational) simulation, but without the recuperator bypass valve concept in order to initially determine how the (baseline) system behaves and can be controlled in order to meet variable heat and power demands; 3) development and initial deployment of the high-temperature recuperator bypass valve technology in order to confirm and characterize the approach; 4) usage of the experimental data for the valve to create a semi-empirical computational model for the bypass valve which could then be combined with the heat exchanger computational models; 5) repeat of the second task of simulating and exploring the system’s performance, but this time including the bypass valve to resolve its efficacy. Tasks were successfully completed, and the general notion of flexibly operating, high electrical efficiency CHHP was further corroborated. Supportive details are provided in the report.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2023

SNM Radiation Signature Classification Using Different Semi-Supervised Machine Learning Models

The timely detection of special nuclear material (SNM) transfers between nuclear facilities is an important monitoring objective in nuclear nonproliferation. Persistent monitoring enabled by successful detection and characterization of radiological material movements could greatly enhance the nuclear nonproliferation mission in a range of applications. Supervised machine learning can be used to signal detections when material is present if a model is trained on sufficient volumes of labeled measurements. However, the nuclear monitoring data needed to train robust machine learning models can be costly to label since radiation spectra may require strict scrutiny for characterization. Therefore, this work investigates the application of semi-supervised learning to utilize both labeled and unlabeled data. As a demonstration experiment, radiation measurements from sodium iodide (NaI) detectors are provided by the Multi-Informatics for Nuclear Operating Scenarios (MINOS) venture at Oak Ridge National Laboratory (ORNL) as sample data. Anomalous measurements are identified using a method of statistical hypothesis testing. After background estimation, an energy-dependent spectroscopic analysis is used to characterize an anomaly based on its radiation signatures. In the absence of ground-truth information, a labeling heuristic provides data necessary for training and testing machine learning models. Supervised logistic regression serves as a baseline to compare three semi-supervised machine learning models: co-training, label propagation, and a convolutional neural network (CNN). In each case, the semi-supervised models outperform logistic regression, suggesting that unlabeled data can be valuable when training and demonstrating value in semi-supervised nonproliferation implementations.

98 NUCLEAR DISARMAMENT, SAFEGUARDS, AND PHYSICAL P↗
DOE OSTI2026

BICEP/Keck. XX. Component-separated Maps of the Polarized Cosmic Microwave Background and Thermal Dust Emission Using Planck and BICEP/Keck Observations through the 2018 Observing Season

We present component-separated polarization maps of the cosmic microwave background (CMB) and Galactic thermal dust emission, derived using data from the BICEP/Keck experiments through the 2018 observing season and Planck. By employing a maximum-likelihood method that utilizes observing matrices, we produce unbiased maps of the CMB and dust signals. We outline the computational challenges and demonstrate an efficient implementation of the component map estimator. We show methods to compute and characterize power spectra of these maps, opening up an alternative way to infer the tensor-to-scalar ratio from our data. We compare the results of this map-based separation method with the baseline BICEP/Keck analysis. Our analysis demonstrates consistency between the two methods, finding an 84% correlation between the pipelines.

cosmic inflation↗
NASA NTRS1974

Space Shuttle - The new baseline

Recent design alterations and refinements in the Space Shuttle program are considered with particular attention to the present baseline Shuttle configurations, performance characteristics, mission profiles, and flight and ground operations. Hardware and software development and testing, propulsion systems, entry trajectory events, and payload capability are covered. The refined Space Shuttle system design is characterized as one reflecting firm technical and economic considerations. Systems development is well under way, with all major contractors progressing on schedule.

Malkin, M. S.↗
NASA NTRS1986

Correlation of processing and sintering variables with the strength and radiography of silicon nitride

A sintered Si3N4-SiO2-Y2O3 composition, NASA 6Y, was developed that reached four-point flexural average strength/standard deviation values of 857/36, 544/33, and 462/59 MPa at room temperature, 1200 and 1370 C respectively. These strengths represented improvements of 56, 38, and 21 percent over baseline properties at the three test temperatures. At room temperature the standard deviation was reduced by over a factor of three. These accomplishments were realized by the iterative utilization of conventional x-radiography to characterize structural (density) uniformity as affected by systematic changes in powder processing and sintering parameters. Accompanying the improvement in mechanical properties was a change in the type of flaw causing failure from a pore to a large columnar beta- Si3N4 grain typically 40 to 80 microns long, 10 to 30 microns wide, and with an aspect ratio of 5:1.

Sanders, W. A.↗
NASA NTRS1986

Correlation of processing and sintering variables with the strength and radiography of silicon nitride

A sintered Si3N4-SiO2-Y2O3 composition, NASA 6Y, was developed that reached four-point flexural average strength/standard deviation values of 857/36, 544/33, and 462/59 MPa at room temperature, 1200 and 1370 C, respectively. These strengths represented improvements of 56, 38, and 21 percent over baseline properties at the three test temperatures. At room temperature the standard deviation was reduced by over a factor of three. These accomplishments were realized by the iterative utilization of conventional X-radiography to characterize structural (density) uniformity as affected by systematic changes in powder processing and sintering parameters. Accompanying the improvement in mechanical properties was a change in the type of flaw causing failure from a pore to a large columnar beta-Si3N4 grain typically 40-80 micron long, 10-30 micron wide, and with an aspect ratio of 5:1.

Sanders, W. A.↗
NASA NTRS1996

Pulsed Plasma Thruster Contamination

Pulsed Plasma Thrusters (PPT's) are currently baselined for the Air Force Mightysat II.1 flight in 1999 and are under consideration for a number of other missions for primary propulsion, precision positioning, and attitude control functions. In this work, PPT plumes were characterized to assess their contamination characteristics. Diagnostics included planar and cylindrical Langmuir probes and a large number of collimated quartz contamination sensors. Measurements were made using a LES 8/9 flight PPT at 0.24, 0.39, 0.55, and 1.2 m from the thruster, as well as in the backflow region behind the thruster. Plasma measurements revealed a peak centerline ion density and velocity of approx. 6 x 10(exp 12) cm(exp -3) and 42,000 m/s, respectively. Optical transmittance measurements of the quartz sensors after 2 x 10(exp 5) pulses showed a rapid decrease in plume contamination with increasing angle from the plume axis, with a barely measurable transmittance decrease in the ultraviolet at 90 deg. No change in optical properties was detected for sensors in the backflow region.

Myers, Roger M.↗
NASA NTRS2006

Arc-Heater Facility for Hot Hydrogen Exposure of Nuclear Thermal Rocket Materials

A hyper-thermal environment simulator is described for hot hydrogen exposure of nuclear thermal rocket material specimens and component development. This newly established testing capability uses a high-power, multi-gas, segmented arc-heater to produce high-temperature pressurized hydrogen flows representative of practical reactor core environments and is intended to serve. as a low cost test facility for the purpose of investigating and characterizing candidate fueUstructura1 materials and improving associated processing/fabrication techniques. Design and development efforts are thoroughly summarized, including thermal hydraulics analysis and simulation results, and facility operating characteristics are reported, as determined from a series of baseline performance mapping tests.

Litchford, Ron J.↗
NASA NTRSDate not supplied

Validation of Fitness for Duty Standards Using Pre- and Post-Flight Capsule Egress and Suited Functional Performance Tasks in Simulated Reduced Gravity

The transition between gravity environments will involve one of the most complex, high-risk phases of any mission. For example, the reduced functional capacity caused by physiological deconditioning adaptations in microgravity coupled with the stressors of re-entry into partial gravity environments will increase risks to crew, even with rigorous adherence to inflight countermeasures. Quantification of the astronauts’ post-landing functional performance is necessary to design ConOps for exploration missions. Specifically, these two high-risk scenarios may be required to be performed soon after gravity transitions: • Nominal and/or emergency unassisted capsule egress task after return to Earth • Planetary extravehicular activity (EVA) soon after landing on Mars or the Moon This study is broken down into two phases. Phase 1: A feasibility study that will assess the overall feasibility and demonstrate the capability to do these tasks shortly after landing. Phase 2: the full Egress Fitness study, which is part of the CIPHER complement. This study uses a task-based approach to characterize functional performance of these high-risk scenarios in long-duration ISS crewmembers before flight and shortly after return to Earth. Prior to any testing, each astronaut subject completes a suit fit check to ensure adequate sizing and a mobility assessment to confirm completion of the EVA tasks. Pilot Egress Fitness pre-flight and post-flight testing includes an Earth-based emergency egress out of a functional capsule mockup and a short Mars gravity EVA simulation including suit donning, hatch egress, ladder descent, task board cable operations, baggage transfer over sand/rocky regolith, alignment with a rear entry port, and suit egress. Pre-flight testing will occur at any time point prior to flight. Post-flight assessment is much more critical with the capsule egress test that will occur 1–4 hours after landing and the planetary EVA approximately 18–36 hours after landing. The CIPHER study will incorporate additional pre-flight sessions, longer EVA tasks that include traverse and geology sampling, and post-flight sessions on R+1, 4, and 8 to characterize the timeframe of recovery. Data collected for both tasks include task completion time, photo, and video. The EVA portion also includes collection of metabolic and heart rate. Pilot Egress Fitness study has completed both baseline and post-flight testing on four astronaut subjects, with all four able to complete post-flight EVA testing and three able to complete postflight capsule egress testing. Preliminary results observe individual physiological variations, which were to be expected but also suggest the need to carefully track the timeline from undock to landing to testing. Furthermore, some task performance instructions and equipment may need to be adjusted to ensure results are primarily physiological. These and other lessons learned will be addressed with minor protocol changes in the full CIPHER Egress Fitness study.

J R Norcross↗
NASA NTRS2000

The Strategy for the Second Phase of Aerobraking Mars Global Surveyor

On February 19, 1999, the Mars Global Surveyor (MGS) spacecraft was able to propulsively establish its mapping orbit. This event followed the completion of the second phase of aerobraking for the MGS spacecraft on February 4, 1999. For the first time, a spacecraft at Mars had successfully employed aerobraking methods in order to reach its desired pre-launch mapping orbit. This was accomplished despite a damaged spacecraft solar array. The MGS spacecraft was launched on November 7, 1996, and after a ten month interplanetary transit was inserted into a highly elliptical capture orbit at Mars on September 12, 1997. Unlike other interplanetary missions, the MGS spacecraft was launched with a planned mission delta-V ((Delta)V) deficit of nearly 1250 m/s. To overcome this AV deficit, aerobraking techniques were employed. However, damage discovered to one of the spacecraft's two solar arrays after launch forced major revisions to the original aerobraking planning of the MGS mission. In order to avoid a complete structural failure of the array, peak dynamic pressure levels for the spacecraft were established at a major spacecraft health review in November 1997. These peak dynamic pressure levels were roughly one-third of the original mission design values. Incorporating the new dynamic pressure limitations into mission replanning efforts resulted in an 'extended' orbit insertion phase for the mission. This 'extended' orbit insertion phase was characterized by two distinct periods of aerobraking separated by an aerobraking hiatus that would last for several months in an intermediate orbit called the "Science Phasing Orbit" (SPO). This paper describes and focuses on the strategy for the second phase of aerobraking for the MGS mission called "Aerobraking Phase 2." This description will include the baseline aerobraking flight profile, the trajectory control methodology, as well as the key trajectory metrics that were monitored in order to successfully "guide' the spacecraft to its desired mapping orbit. Additionally, the actual aerobraking progress is contrasted to the planned aerobraking flight profile. (A separate paper will describe the navigation aspects of MGS aerobraking in detail.) Key to the success of the MGS mission is the delivery of the spacecraft to its final mapping orbit and the synergy the instrument complement provides to its scientific investigators when science data is returned from that orbit. The MGS mapping orbit is characterized as a low altitude, near-circular, near-polar orbit that is Sun-synchronous with the descending equatorial crossing at 2:00 AM local mean solar time (LMST).

Johnston, M. D.↗
DOE OSTI2022

The Effect of APS-HVOF Bond Coating Thickness Ratio on TBC Furnace Cycle Lifetime

In this work, combinations of NiCoCrAlY APS and high-velocity oxygen fuel (HVOF) bond coatings were deposited on alloy 247 disk substrates with APS yttria-stabilized zirconia (YSZ) top coatings to assess the benefit of air plasma sprayed (APS) ‘flash’ bond coatings. Using 1-h cycles at 1100 °C in air with 10% H 2 O and HVOF-only and APS-only bond coatings as a baseline, it was found that APS flash coatings extended the average coating lifetime by 16% to 35% with the thicker flash coating performing best. Principal component analysis and energy dispersive spectroscopy (EDS) compositional mapping on coatings characterized after 0, 100, 300 and 500 cycles and after failure showed that the Al in the bond coatings was depleted due to both oxidation and back diffusion into the substrate. The APS-only bond coating had significant oxidation throughout the bond coating and was so depleted in Al, that Al diffused from the substrate to the coating. Residual stress maps of the thermally-grown alumina scale were obtained every 100 cycles using photo-stimulated luminescence piezospectroscopy (PLPS) revealing that the Thick Flash coating had the slowest rate of damage accumulation in the oxide scale.

alumina scale↗
DOE OSTI2021

Comprehensive powertrain modeling for heavy-duty applications: A study of plug-in hybrid electric bus

A comprehensive forward-looking powertrain model with an efficiency-based control strategy was developed to achieve real-time optimization of plug-in hybrid electric buses while considering the real vehicle drivability and the practical operation of all powertrain components under real driving conditions. The control strategy is based on a supervisory control algorithm that alternately employs charge-dominant control and discharge-dominant control to manage multiple powertrain sources, and enable an optimal overall efficiency-based powertrain operation state by maximizing the inherent optimal powertrain efficiency through best all transmission gear choice and the blend of motor and/or engine power. In the model, a component energy efficiency database was developed to rapidly enable an smart and optimal operating state determined from a set of efficiency maps characterizing the component and powertrain control states as a function of the instantaneous vehicle operational condition. The results revealed that the energy savings achieved with the innovative powertrain control improved by 10%–30% compared with the baseline hybrid powertrain control strategy. The benefits of eco-driving with respect to energy consumption were also evaluated using the powertrain model. The powertrain control model was implemented into a real hybrid bus. Measured energy savings with the optimized control strategy were similar to the simulated results.

33 ADVANCED PROPULSION SYSTEMS↗
DOE OSTI2020

Impact of undoped substrates on high performance silicon solar cells

Today's highest-efficiency silicon solar cells typically operate near the threshold between low-level and high-level injection. It is not well understood if pushing further into a regime in which the cell operating point is solidly in high-level injection at all times of the day has further benefits for the solar cell performance. From a reliability perspective, cells fabricated on lower doped silicon have a larger breakdown voltage. This advantage can affect the design of modules allowing higher voltages and a relaxation of the number of bypass diodes needed. In this project, we present a comprehensive assessment, both experimental and using simulation, of how bulk resistivity, light intensity, and operation temperature impact the performance of the silicon solar cell. This work incorporates a comprehensive device physics analysis assisted by numerical simulation. The source code is now available under General Public License (GPL3), and to further leverage the findings of this project and outreach people outside of the scientific community, we are working with www.pveducation.org (which receives >1 million visitors a year) to create interactive content using our simulation results. The simulation results indicate that high bulk resistivity wafers (>>10 Ωcm) require bulk Shockley-Read-Hall (SRH) lifetimes in the millisecond range to outperform wafers with standard bulk resistivities (<10 Ωcm). Additionally, above bulk resistivities of 10 Ωcm (the exact value depends on the bulk characteristics of the wafer), the cell efficiency is weakly dependent on the bulk resistivity. As a result, ingot manufactures may have an opportunity to further reduce wafer cost by growing higher resistivity ingots that are more tolerant to resistivity variations. This project is particularly relevant today, as solar cell architectures with improved surface passivation and milliseconds lifetimes wafers are commercially available, leveraging potential benefits of using higher bulk resistivities. Outside of interdigitated back contact (IBC) cell, reported studies on high resistivity silicon (>100 Ωcm) are very limited. To the best of our knowledge, this project provides for the first-time experimental insight on solar cells fabricated on wafers with bulk resistivities up to several thousand Ωcm, delivering a comprehensive vision of their performance under real-world temperature and light intensity operation conditions. We manufactured and characterized solar cells with bulk resistivities in the range of 1 Ωcm to >15k Ωcm. Under standard testing conditions (STC), we measured solar cells efficiencies over 20% over the entire range of bulk resistivities, using our baseline cell processing. To evaluate the cell performance in real-world operation conditions, the solar cells were measured at different temperatures (25-80°C) and at different light intensities (0.1-1 suns). The measurements show that the bulk resistivity does not impact the solar cell response to temperature and light intensity. Similar thermal coefficients (TC) were measured for standard and high bulk resistivities, and they are comparable with the TC values reported in the literature for standard bulk resistivities <10 Ωcm. After light soaking, the solar cell didn’t show signs of light-induced degradation (LID). This result was expected since n-type float zone (FZ) wafers were used in this work, i.e. low traces of boron and low concentration of oxygen (oxygen is typically found in the seed end of Czochralski (CZ) ingots). We measured for high bulk resistivities (>10 Ωcm) extremely high breakdown voltages (>1000V). In conclusion, the insight provided by this project can positively impact the levelized cost of energy (LCOE) of the photovoltaic systems through its effect on cell and ingot manufacturing yield, silicon cell power output, and module reliability.

14 SOLAR ENERGY↗