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

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All sourcesNASA NTRSDOE OSTI
NASA NTRS1981

Development of low cost custom hybrid microcircuit technology

Selected potentially low cost, alternate packaging and interconnection techniques were developed and implemented in the manufacture of specific NASA/MSFC hardware, and the actual cost savings achieved by their use. The hardware chosen as the test bed for this evaluation ws the hybrids and modules manufactured by Rockwell International fo the MSFC Flight Accelerometer Safety Cut-Off System (FASCOS). Three potentially low cost packaging and interconnection alternates were selected for evaluation. This study was performed in three phases: hardware fabrication and testing, cost comparison, and reliability evaluation.

Perkins, K. L.↗
DOE OSTI2022

Achieving American Leadership in the Solar Photovoltaics Supply Chain Factsheet

Developing U.S. photovoltaic (PV) manufacturing could mitigate global supply chain challenges and lead to tremendous benefits for the climate as well as for U.S. workers, employers, and the economy. The solar supply chain is global and reliant on products from China or companies with close ties to China. Significant growth in U.S. manufacturing across the supply chain is possible with incentives that offset the higher cost of manufacturing in the United States. Existing polysilicon production facilities are currently idle or supplying polysilicon to other industries. Expansion in the ingot and wafer sectors outside of China would create demand for existing U.S. polysilicon producers to run at high capacity. The United States can expand production of thin-film modules, which do not rely on obtaining materials from Chinese companies. The thin film supply chain is concentrated in Ohio. There is a cluster of solar module manufacturers in Alabama, Florida, and Georgia, which presents an opportunity to grow a competitive supply chain of module components in the region.

Source record↗
DOE OSTI2016

Performance and Reliability of Bonded Interfaces for High-Temperature Packaging. Annual Report

Current generation automotive power electronics packages utilize silicon devices and lead-free solder alloys. To meet stringent technical targets for 2020 and beyond (for cost, power density, specific power, efficiency and reliability), wide-bandgap devices are being considered since they offer advantages such as operation at higher frequencies, voltages, and temperatures. Traditional power electronics packages must be redesigned to utilize the full potential of wide-bandgap devices, and the die- and substrate-attach layers are key areas where new material development and validation is required. Present solder alloys do not meet the performance requirements for these new package designs while also meeting cost and hazardous substance restrictions. Sintered silver (Ag) promises to meet the needs for die- and substrate-attach interfaces but synthesis optimization and reliability evaluation must be completed. Sintered Ag material was proposed as an alternative solution in power electronics packages almost 20 years back. However, synthesis pressure requirements up 40 MPa caused a higher complexity in the production process and more stringent flatness specifications for the substrates. Recently, several manufacturers have developed sintered Ag materials that require lower (3-5 MPa) or even no bonding pressures. Degradation mechanisms for these sintered Ag materials are not well known and need to be addressed. We are addressing these aspects to some extent in this project. We are developing generalized (i.e., independent of geometry) stress intensity factor versus cycles-to-failure relations for sintered Ag. Because sintered Ag is a relatively new material for automotive power electronics, the industry currently does not have a good understanding of recommended synthesis parameters or expected reliability under prescribed conditions. It is an important deliverable of this project to transfer findings to industry to eliminate barriers to using sintered Ag as a viable and commercialized die- and substrate-attach material. Only a few manufacturers produce sintered Ag pastes and may consider some processing conditions as proprietary. It is the goal of this project to openly explore and define best practices in order to impact the maximum number of power electronics module manufacturers and suppliers.

30 DIRECT ENERGY CONVERSION↗
DOE OSTI2016

Development of Cu(In,Ga)Se2 Test Coupons for Potential Induced Degradation Studies

We report on the design, fabrication and accelerated testing of fully encapsulated small area coupons (approximately 7.5cm x 7.5 cm) for the purpose of researching potential induced degradation in Cu(In, Ga)Se2 based PV modules. The fabrication of these coupons enables the study of the solar cells and the materials used in PV module manufacturing such as top and bottom glass covers of different composition (soda-lime glass, high temperature glass, alkaline-free glass, etc), plastic-based top covers, ethylene vinyl acetate and edge seal encapsulation materials. The coupons can also be used to emulate framed and frameless modules that utilize either monolithically interconnected modules or singular cell type of modules. The design of the coupons, their fabrication, the materials used and their testing for 1000 hours under 85 degrees C and 85% RH conditions are presented.

14 SOLAR ENERGY↗
DOE OSTI2023

Bifacial PV Module Energy Modeling Validation Study

The cost delta between monofacial and bifacial photovoltaic (PV) modules was decreasing in 2018 when this study was initially proposed, making bifacial modules an attractive offering. However, there were limited field studies available that could be considered utility-scale representative, and PV module manufacturers were stating large ranges for the expected energy yield improvements of bifacial technology. This generated uncertainties regarding bifacial performance gains and the actual LCOE (levelized cost of energy). There was also relatively low confidence in the industry’s energy modeling tools’ ability to accurately predict bifacial energy yield, meaning that early adopters of bifacial modules were not able to fully account for the increased energy yield in their energy and financial models. The intent of this project was to provide the solar industry with greater certainty on the energy yield gains of bifacial modules and provide higher confidence in the ability for different energy modeling software to model bifacial PV site performance. Achieving this would allow for bifacial technology to become bankable (i.e. accepted by Independent Engineers, site financiers and other PV site stakeholders), offering a step change in PV site performance that had not been seen since the widespread adoption of the single-axis tracker. Over the course of this study other economic factors including a significant tariff exemption for bifacial modules resulted in accelerated adoption of bifacial technology throughout the US utility scale solar segment. The number of early adopters increased rapidly, and with many investors accepting this module choice the question of bifacial bankability was seemingly answered faster than expected. However, PVEL’s study has still achieved significant accomplishments in demonstrating the accuracy of bifacial modeling across three different software platforms. The results of this study have shown that the mean biased error (MBE) between the field data and the predicted values from all three software platforms were aligned with a maximum MBE of 1.3% and a minimum MBE of -1.8%.

14 SOLAR ENERGY↗
DOE OSTI2015

Quantifying Solar Cell Cracks in Photovoltaic Modules by Electroluminescence Imaging

This article proposes a method for quantifying the percentage of partially and totally disconnected solar cell cracks by analyzing electroluminescence images of the photovoltaic module taken under high- and low-current forward bias. The method is based on the analysis of the module's electroluminescence intensity distribution, applied at module and cell level. These concepts are demonstrated on a crystalline silicon photovoltaic module that was subjected to several rounds of mechanical loading and humidity-freeze cycling, causing increasing levels of solar cell cracks. The proposed method can be used as a diagnostic tool to rate cell damage or quality of modules after transportation. Moreover, the method can be automated and used in quality control for module manufacturers, installers, or as a diagnostic tool by plant operators and diagnostic service providers.

14 SOLAR ENERGY↗
DOE OSTI2019

Book: Advanced Nano and Micro materials for Photovoltaics: future and emerging technologies, Chapter 11: "Multifunctional Optical Coatings and Light Management for Photovoltaics"

In this chapter, we present a discussion of three main topics in coatings and light management for PV. First, we will cover the basic principles behind light management and broadly discuss approaches that can be used to mitigate reflective losses. Additionally, we build further on this topic by exploring the specific antireflection techniques used by PV glass and module manufacturers. Next, we explore antisoiling coatings, a relatively understudied area until recently. We comment on the distinctly different approaches to antisoiling coatings currently being explored by the PV community and the pros and cons of each. In addition, antisoiling coatings can also serve as antireflective coatings, providing a route to multifunctional coatings. Finally, we comment briefly on possible rich areas for new research efforts that we believe will provide a meaningful impact on solar module efficiency, reliability, and durability.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2015

Development of ITM oxygen technology for integration in IGCC and other advanced power generation

Ion Transport Membrane (ITM) technology is based on the oxygen-ion-conducting properties of certain mixed-metal oxide ceramic materials that can separate oxygen from an oxygen-containing gas, such as air, under a suitable driving force. The “ITM Oxygen” air separation system that results from the use of such ceramic membranes produces a hot, pure oxygen stream and a hot, pressurized, oxygen-depleted stream from which significant amounts of energy can be extracted. Accordingly, the technology integrates well with other high-temperature processes, including power generation. Air Products and Chemicals, Inc., the Recipient, in conjunction with a dozen subcontractors, developed ITM Oxygen technology under this five-phase Cooperative Agreement from the laboratory bench scale to implementation in a pilot plant capable of producing power and 100 tons per day (TPD) of purified oxygen. A commercial-scale membrane module manufacturing facility (the “CerFab”), sized to support a conceptual 2000 TPD ITM Oxygen Development Facility (ODF), was also established and operated under this Agreement. In the course of this work, the team developed prototype ceramic production processes and a robust planar ceramic membrane architecture based on a novel ceramic compound capable of high oxygen fluxes. The concept and feasibility of the technology was thoroughly established through laboratory pilot-scale operations testing commercial-scale membrane modules run under industrial operating conditions with compelling lifetime and reliability performance that supported further scale-up. Auxiliary systems, including contaminant mitigation, process controls, heat exchange, turbo-machinery, combustion, and membrane pressure vessels were extensively investigated and developed. The Recipient and subcontractors developed efficient process cycles that co-produce oxygen and power based on compact, low-cost ITMs. Process economics assessments show significant benefits relative to state-of-the-art cryogenic air separation technology in energy-intensive applications such as IGCC with and without carbon capture.

Armstrong, Phillip A.↗
DOE OSTI2021

Development of Integrated Mechanical Pods

This presentation highlights early wins, updated progress, and upcoming developments on ‘national-scale shared development platform’ for rapid prototyping, testing and validation of various integrated Mechanical Pod solutions and form factors. Such pod solutions consist of a set of all-electric heat pump mechanical equipment that have integrated functionalities through built-in controls, with heating, cooling, hot water, ventilation (including energy recovery), electrical management, and battery storage within a single package. The presentation draws inspiration from the success of bathroom pods in the US modular construction industry, UK’s efforts with unitizing mechanical systems as ‘utility cupboards’, and VEIC’s early wins in design-build of all-electric Mechanical Pod solutions in Vermont. The presentation includes researchers and partners involved with NREL in Design for Manufacturing and Assembly (DfMA), Virtual Design and Construction (VDC), and digital twin based process optimization modeling of integrated Mechanical Pod solutions. The presentation aims to highlight early wins from such a platform and how various physical and virtual tools are currently being employed as part of NREL’s ongoing multi-year project funded by US DOE. Streamlined procurement, coordination, installation, and O&M of Mechanical Pods such that the majority of work is delegated to the off-site modular factory implies monetary savings. Such a seemingly basic shift in location of the construction process leads to great reduction in complexity, first cost, lead time, and waste, and greater opportunities for innovative compartmentalization and integration of mechanical systems appropriately sized for each apartment or hotel guest room. However, past studies on unitized combination systems show that high installation costs, maintenance issues, challenges with system integration, limitations in existing electrical infrastructure, and lack of architecturally appealing solutions are key barriers. NREL and partners aim to address key barriers through DfMA approach, rapid prototyping and testing, and digital twin process optimization modeling. The presentation is also a call for interested entities to partner with NREL as part of the national-scale development platform, help drive both product and process innovation, and encourage open source sharing of learnings. Learning objectives include (1) learn about the vision of national-scale shared development platform for process-product innovation on integrated mechanical pod solutions and how to get involved, (2) gain an understanding of the components of an all-electric, high performance home, design characteristics and equipment included in an all-electric mechanical pod, integration of mechanical systems within a modular factories’ assembly line, and the system’s commissioning, operation and maintenance. The pre-planning and coordination with the factory and sub-contractors are also highlighted, (3) gain an understanding of using process modeling tools to quantify resource-constrained performance of operations (such as integration of energy efficiency strategies) to manufacture modules of varying design, (4) gain insights on virtual design, rapid prototyping, and emulated testing of various form factors across different climatic conditions. The need for such preliminary testing with open source sharing of learnings will also be highlighted.

30 DIRECT ENERGY CONVERSION↗
DOE OSTI2020

Characterizing photovoltaic backsheet adhesion degradation using the wedge and single cantilever beam tests, Part I: Field Modules

Photovoltaic backsheets are exposed to harsh outdoor weathering conditions throughout their service lives that can compromise their protective function, through adhesive debonding between their constituent layers and between the backsheet and the module. We report a large-scale study on adhesive degradation was conducted on 37 field-exposed modules, that spanned 19 different module manufacturers, that were deployed among six Köppen–Geiger climatic zones, and that were fielded between 0 and 28 years. Six outer layer polymer classes were identified among the backsheets: polyamide (PA), polyethylene terephthalate (PET), polyvinyl fluoride (PVF), polyvinylidene fluoride (PVDF), fluoroethylene vinyl ether copolymer (FEVE), and tetrafluoroethylene hexafluoropropylene vinylidene fluoride copolymer (THV). Two adhesion tests were used to measure the adhesive strength: the wedge test and the width-tapered single-cantilever beam (SCB) test. Adhesion energies were compared across exposure time and Köppen–Geiger climatic zone. Many of the PET-, PVF-, and PVDF-based backsheets experienced degradation of the adhesive layer between the backsheet outer and core layers. A consistent trend of decreasing adhesion energy with exposure time was observed in five out of the six backsheet types. Trends among adhesion energy and climatic zone, while expected, were not observed, possibly due to broad ranges in temperature, humidity, and precipitation defining Köppen–Geiger climatic zones. The cantilever beam measurements produced an upper cutoff of approximately 100 J/m 2 , above which no modules exhibited field delamination. The results are part of a two-part study quantifying adhesion in both field-weathered and indoor-exposed PV backsheets.

14 SOLAR ENERGY↗
DOE OSTI2018

System Dynamics of Polysilicon for Solar Photovoltaics: A Framework for Investigating the Energy Security of Renewable Energy Supply Chains

Renewable energy, produced with widely available low-cost energy resources, is often included as a component of national strategies to address energy security and sustainability. Market and political forces cannot disrupt the sun or wind, unlike oil and gas supplies. However, the cost of renewable energy is highly dependent on technologies manufactured through global supply chains in leading manufacturing countries. The countries that contribute to the global supply chains may take actions that, directly or indirectly, influence global access to materials and components. For example, high-purity polysilicon, a key material in solar photovoltaics, has experienced significant price fluctuations, affecting the manufacturing capacity and cost of both polysilicon and solar panels. This study has developed and validated an initial system dynamics framework to gain insights into global trade in polysilicon. The model represents an initial framework for exploration. Three regions were modeled-China, the United States, and the rest of the world - for a range of trade scenarios to understand the impacts of import duties and non-price drivers on the relative volumes of imports and domestic supply. The model was validated with the historical case of China imposing an import duty on polysilicon from the United States, the European Union, and South Korea, which altered the regional flows of polysilicon - in terms of imports, exports, and domestic production-to varying degrees. As expected, the model tracked how regional demand shares and influx volumes decrease as a duty on a region increases. Using 2016 as a reference point, in the scenarios examined for U.S. exports to China, each 10% increase in the import duty results in a 40% decrease in import volume. The model also indicates that, under the scenarios investigated, once a duty has been imposed on a region, the demand share from that region declines and does not achieve pre-duty levels, even as global demand increases. Adding additional countries and other components in the photovoltaic supply chain (panels, cells, wafers) to this model could enable policymakers to better understand the relative impact of trade measures across the entire photovoltaic module manufacturing supply chain and the conditions that encourage industry evolution and competitiveness.

14 SOLAR ENERGY↗
DOE OSTI2016

Technology advances needed for photovoltaics to achieve widespread grid price parity: Widespread grid price parity for photovoltaics

To quantify the potential value of technological advances to the photovoltaics (PV) sector, this paper examines the impact of changes to key PV module and system parameters on the levelized cost of energy (LCOE). The parameters selected include module manufacturing cost, efficiency, degradation rate, and service lifetime. NREL's System Advisor Model (SAM) is used to calculate the lifecycle cost per kilowatt-hour (kWh) for residential, commercial, and utility scale PV systems within the contiguous United States, with a focus on utility scale. Different technological pathways are illustrated that may achieve the Department of Energy's SunShot goal of PV electricity that is at grid price parity with conventional electricity sources. In addition, the impacts on the 2015 baseline LCOE due to changes to each parameter are shown. These results may be used to identify research directions with the greatest potential to impact the cost of PV electricity.

14 SOLAR ENERGY↗
DOE OSTI2025

High-Intensity UV Exposure for the Rapid Screening of Silicon Photovoltaic Architectures

Advanced Si photovoltaic architectures incorporate different materials and processing pathways that influence degradation modes. Ultraviolet-induced degradation (UVID) is an understudied degradation mode for advanced cell architectures and is of increasing concern to industry due to growing adoption of UV-transparent encapsulation and bifacial technologies. In order to adopt new and evolving technologies confidently, novel component materials and processing techniques must be evaluated and designed for long-term stability, in addition to the conventional design focus on efficiency. In this work, a study protocol framework is presented for the rapid screening of unencapsulated devices against UVID. Unencapsulated passivated emitter rear contact (PERC) and tunnel oxide passivated contact (TOPCon) devices were aged under different UV irradiance intensities and measured via conventional nondestructive electrical characterization methods to assess performance degradation. Based on the results, protocol efficacy and recommendations for further study are discussed. As a result, this work is part of a broader effort to develop rapid screening processes that cut across architectures and exposure conditions to aid module manufacturers in vetting new materials choices for long-term stability.

Accelerated exposure↗
DOE OSTI2015

DOE SunShot (FY15 Final Technical Report)

Sandia National Laboratories (Sandia) manages four of the five PV Regional Test Centers (RTCs). This report reviews accomplishments made by the four Sandia-managed RTCs during FY2015 (October 1, 2014 to September 30, 2015) as well as some programmatic improvements that apply to all five sites. The report is structured by Site first then by Partner within each site followed by the Current and Potential Partner summary table, the New Business Process, and finally the Plan for FY16 and beyond. Since no official SOPO was ever agreed to for FY15, this report does not include reporting on specific milestones and go/no-go decisions. The RTCs validate new solar technologies and system configurations, demonstrating performance and reliability under field conditions over time. There are five sites representing a range of climate conditions (NREL manages the Colorado site). The RTCs provide technical assistance to solar companies in the US. This program has shifted its focus, along with the industry, from validation of large systems to more targeted studies of small systems designed to compare sub-arrays of different module technologies. In addition, the RTCs are actively seeking partners from both module manufacturers and balance-of-systems producers.

14 SOLAR ENERGY↗
NASA NTRS1977

Space industrialization studies - An overview

An overview of NASA's current planning for a space industrialization program is described as an introduction to the papers on Space Industrialization being presented by Rockwell International Corporation and Science Applications Incorporated. Background information is presented that outlines the integrated planning process which resulted in specific long range goals and objectives being formulated for NASA programs in technology, environment, resources, earth science, communications, space exploration, aeronautics, and an expanded application of space called space industrialization. Program objectives for NASA's Industrialization of Space and studies on potential near term supporting elements (Space Platform, Large Space Structures, Orbital Operations Capabilities Development, Space Manufacturing Module) are discussed.

Priest, C.↗
NASA NTRS1979

Investigation of Test Methods, Material Properties, and Processes for Solar Cell Encapsulants

The reformulation of a commercial grade of ethylene/vinyl acetate copolymer for use as a pottant in solar cell module manufacture was investigated. Potentially successful formulations were prepared by compounding the raw polymer with antioxidants, ultraviolet absorbers and crosslinking agents to yield stabilized and curable compositions. The resulting elastomer was found to offer low cost (approximately $0.80/lb.), low temperature processability, high transparency (91% transmission), and low modulus. Cured specimens of the final formulation endured 4000 hours of fluorescent sunlamp radiation without change which indicates excellent stability.

Willis, P. B.↗
NASA NTRS1982

Equipment development for automated assembly of solar modules

Prototype equipment was developed which allows for totally automated assembly in the three major areas of module manufacture: cell stringing, encapsulant layup and cure and edge sealing. The equipment is designed to be used in conjunction with a standard Unimate 2000B industrial robot although the design is adaptable to other transport systems.

Hagerty, J. J.↗
NASA NTRS1985

Glass breaking strength: The role of surface flaws and treatments

Although the intrinsic strength of silicon dioxide glass is of the order of 10 to the 6th power lb/sq in, the practical strength is roughly two orders of magnitude below this theoretical limit, and depends almost entirely on the surface condition of the glass, that is, the number and size of flaws and the residual surface compression (temper) in the glass. Glass parts always fail in tension when these flaws grow under sustained loading to some critical size. Research associated with glass encapsulated crystalline-Si photovoltaic (PV) modules has greatly expanded our knowledge of glass breaking strength and developed sizeable data base for commercially available glass types. A detailed design algorithm is developed for thickness sizing of rectangular glass plates subject to pressure loads. Additional studies examine the strength of glass under impact loading conditions such as that caused by hail. Although the fundamentals of glass breakage are directly applicable to thin film modules, the fracture strength of typical numerical glass must be replaced with data that reflect the high temperature tin oxide processing, laser scribing, and edge processing peculiar to thin film modules. The fundamentals of glass breakage applicable to thin film modules and preliminary fracture strength data for a variety of 1 ft square glass specimens representing preprocessed and post processed sheets from current amorphous-Si module manufacturers are presented.

Moore, D.↗