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At least 937 records · Page 52

Evaluation of Voronoi Meshes for Large Eddy Simulations of High Lift Aerodynamics

Numerical sensitivity to 3 different Voronoi seeding methods is investigated for Large Eddy Simulations (LES). A second order accurate, non-dissipative finite volume discretization is used to systematically investigate the effects of different polyhedral Voronoi mesh types using a sequence of three canonical problems with increasing complexity. First, inviscid isentropic vortex propagation is studied to demonstrate the substantial reduction of errors for rhombic dodecahedron and truncated octahedral cell types over Cartesian hexagonal cells of identical spacing. Furthermore, the reduction of errors induced at cell-size transitions (grid-coarsening interfaces) due to Lloyd smoothing iterations is quantified. It is shown that by utilizing an appropriate viscous flux discretization, a constant coefficient subgrid scale model is sufficient for non-linear stability at the 2:1 cell-size transitions on polyhedral grids, although some further error reduction does occur when smoothing is utilized. Next, forced homogeneous isotropic turbulence at an asymptotically large Reynolds number is studied to demonstrate the non-dissipative character of the inviscid flux discretization, and the non-linear robustness and accuracy offered by the viscous flux discretization using a subgrid scale model for all three Voronoi grid types. Finally, Wall-Modeled Large Eddy Simulations (WMLES) are performed to study the high-lift aerodynamics on the McDonnell Douglas 30P30N multi-element airfoil at two distinct grid levels and for two distinct Voronoi cell types. The formulation is shown to predict the aerodynamic loading with high accuracy at all angles of attack when sufficient resolution is reached, and the hexagonal prism grid topology, while computationally more expensive, has higher effective resolution compared to the Cartesian grid topology with the same spacing.

TTT↗

Adaptive Inverse Control for Rotorcraft Vibration Reduction

This thesis extends the Least Mean Square (LMS) algorithm to solve the mult!ple-input, multiple-output problem of alleviating N/Rev (revolutions per minute by number of blades) helicopter fuselage vibration by means of adaptive inverse control. A frequency domain locally linear model is used to represent the transfer matrix relating the higher harmonic pitch control inputs to the harmonic vibration outputs to be controlled. By using the inverse matrix as the controller gain matrix, an adaptive inverse regulator is formed to alleviate the N/Rev vibration. The stability and rate of convergence properties of the extended LMS algorithm are discussed. It is shown that the stability ranges for the elements of the stability gain matrix are directly related to the eigenvalues of the vibration signal information matrix for the learning phase, but not for the control phase. The overall conclusion is that the LMS adaptive inverse control method can form a robust vibration control system, but will require some tuning of the input sensor gains, the stability gain matrix, and the amount of control relaxation to be used. The learning curve of the controller during the learning phase is shown to be quantitatively close to that predicted by averaging the learning curves of the normal modes. For higher order transfer matrices, a rough estimate of the inverse is needed to start the algorithm efficiently. The simulation results indicate that the factor which most influences LMS adaptive inverse control is the product of the control relaxation and the the stability gain matrix. A small stability gain matrix makes the controller less sensitive to relaxation selection, and permits faster and more stable vibration reduction, than by choosing the stability gain matrix large and the control relaxation term small. It is shown that the best selections of the stability gain matrix elements and the amount of control relaxation is basically a compromise between slow, stable convergence and fast convergence with increased possibility of unstable identification. In the simulation studies, the LMS adaptive inverse control algorithm is shown to be capable of adapting the inverse (controller) matrix to track changes in the flight conditions. The algorithm converges quickly for moderate disturbances, while taking longer for larger disturbances. Perfect knowledge of the inverse matrix is not required for good control of the N/Rev vibration. However it is shown that measurement noise will prevent the LMS adaptive inverse control technique from controlling the vibration, unless the signal averaging method presented is incorporated into the algorithm.

Jacklin, Stephen A.↗

Enhanced Menshutkin S N 2 Reactivity in Mesoporous Silica: The Influence of Surface Catalysis and Confinement

A significant enhancement in the Menshutkin S N 2 reaction between 1-methylimidazole (MeIm) and methyl thiocyanate (MeSCN) is observed when the reaction is confined in the nanoscale silica pores of MCM41 and SBA15. The experiments in the silica pores are conducted without surrounding bulk reaction mixture. The influences of temperature, pore radius, and surface chemistry on the kinetics of the confined reaction are analyzed with time-dependent infrared spectroscopy, molecular dynamics simulations, and ab initio calculations. The rate constant of the pseudo-first order reaction increases with decreasing pore size, and the activation energy is found to decrease by 5.6 kJ/mol in the smallest pore studied (2.8 nm) relative to the bulk reaction. The rate constant dependence on pore size is accurately described by a two-state model in which molecules within the 4.6 Å interfacial layer experience a 2.4-fold rate constant increase relative to those reacting at the bulk rate further away from the interface. The removal of polar silanol groups from the silica surface via passivation with trimethylsilyl chloride results in bulk-like kinetics despite a reduction in the pore diameter, demonstrating the role of silanols as catalytic sites. Here, electronic structure calculations of the energy profile on a model silica surface confirm that silanol groups, particularly those of the vicinal type, can reduce the activation energy and reaction endothermicity through the donation of hydrogen bonds to the reactant, transition state, and product complexes.

36 MATERIALS SCIENCE↗

Improved Heralded Single-Photon Source with a Photon-Number-Resolving Superconducting Nanowire Detector

Deterministic generation of single photons is essential for many quantum information technologies. A bulk optical nonlinearity emitting a photon pair, where the measurement of one of the photons heralds the presence of the other, is commonly used with the caveat that the single-photon emission rate is constrained due to a trade-off between multiphoton events and pair emission rate. Using an efficient and low noise photon-number-resolving superconducting nanowire detector we herald, in real time, a single photon at telecommunication wavelength. We perform a second-order photon correlation g 2 ( 0 ) measurement of the signal mode conditioned on the measured photon number of the idler mode for various pump powers and demonstrate an improvement of a heralded single-photon source. We develop an analytical model using a phase-space formalism that encompasses all multiphoton effects and relevant imperfections, such as loss and multiple Schmidt modes. We perform a maximum-likelihood fit to test the agreement of the model to the data and extract the best-fit mean photon number μ of the pair source for each pump power. A maximum reduction of 0.118 ± 0.012 in the photon g 2 ( 0 ) correlation function at μ = 0.327 ± 0.007 is obtained, indicating a strong suppression of multiphoton emissions. For a fixed g 2 ( 0 ) = 7 × 10 − 3 , we increase the single pair generation probability by 25%. Our experiment, built using fiber-coupled and off-the-shelf components, delineates a path to engineering ideal sources of single photons.

Davis, Samantha I.↗

Does The Earth Have an Adaptive Infrared Iris?

Observations and analyses of water vapor and clouds in the tropics over the past decade suggest a different approach to radiative climate feedbacks: namely, that high clouds and high free-tropospheric relative humidity are largely tied to each other, and that the main feedback consists in changing the relative areas of cloudy/moist regions vis a vis clear/dry regions in response to the surface temperature of the cloudy/moist regions - as opposed to altering the humidity in either of the regions. This is an intrinsically 2-dimensional (horizontal and vertical) effect which does not readily enter simple 1-dimensional (vertical) radiative-convective schemes which emphasize average humidity, etc. Preliminary analyses of cloud data for the eastern part of the Western Pacific from the Japanese GMS-5(Geostationary Meteorological Satellite), are supportive of this suggestion - pointing to a 15% reduction in cloudy/moist area for a 1C increase of the sea surface temperature as measured by the cloud-weighted SST (sea surface temperature). The implication of this result is examined using a simple 2-dimensional radiative-convective model. The calculations show that such a change in the tropics would lead to a strong negative feedback in the global climate, with a feedback factor of about -1.7, which, if correct, would easily dominate the positive water vapor feedback found in current models. This new feedback mechanism, in effect, constitutes an adaptive infrared iris that opens and closes in order to control the OLR (outgoing longwave radiation) in response to changes in surface temperature in a manner similar to the way in which an eye's iris opens and closes in response to changing light levels. The climate sensitivity resulting from this thermostatic mechanism is consistent with the independent determination by Lindzen and Giannitisis (1998). Preliminary attempts to replicate observations with GCMs (General Circulation Models) suggest that models lack such a negative cloud/moist areal feedback.

Lindzen, Richard S.↗

Lunar Surface Stirling Power Systems Using Am-241

For many years NASA has used the decay of Pu-238 (in the form of the General Purpose Heat Source (GPHS)) as a heat source for Radioisotope Thermoelectric Generators (RTG), which have provided electrical power for many NASA missions. While RTG's have an impressive reliability record for the missions in which they have been used, their relatively low thermal to electric conversion efficiency (-5% efficiency) and the scarcity of Plutoinium-238 (Pu-238) has led NASA to consider other power conversion technologies. NASA is considering returning both robotic and human missions to the lunar surface and, because of the long lunar nights (14 earth days) isotope power systems are an attractive candidate to generate electrical power. NASA is currently developing the Advanced Stirling Radioisotope Generator (ASRG) as a candidate higher efficiency power system that produces greater than 160 watts with 2 GPHS modules at the beginning of life (BOL) (-30% efficiency). The ASRG uses the same Pu-238 GPHS modules, which are used in RTG, but by coupling them to a Stirling convertor provides a 4-fold reduction in the number of GPHS modules. This study considers the use of Americium 241 (Am-241) as a substitute for the Pu-238 in Stirling convertor based Radioisotope Power Systems (RPS) for power levels from 1 O's of watts to 5 kWe. The Am-241 is used as a replacement for the Pu-238 in GPHS modules. Depending on power level, different Stirling heat input and removal systems are modeled. It was found that substituting Am-241 GPHS modules into the ASRG reduces power output by about 1/5 while maintaining approximately the same system mass. In order to obtain the nominal 160 watts electrical output of the Pu-238 ASRG requires 10 Am-241 GPHS modules. Higher power systems require changing from conductive coupling heat input and removal from the Stirling convertor to either pumped loops or heat pipes. Liquid metal pumped loops are considered as the primary heat transportation on the hot end and water pumped loop/heat pipe radiator is considered for the heat rejection side for power levels above 1 kWe.

Schmitz, Paul C.↗

Promoting the regulatory acceptance of combined ion and neutron irradiation for material degradation in nuclear reactors

The Advanced Materials and Manufacturing Technologies (AMMT) program within the Department of Energy (DOE) Office of Nuclear Energy has developed its current recommendation for promoting the use of combined ion irradiation and neutron irradiation for the accelerated qualification of materials to be deployed in nuclear reactors. This plan is intended to provide a collaborative path forward that can be adopted by academia, national laboratories, and industry, and has been developed with input from the regulatory research arm of the U.S. Nuclear Regulatory Commission (NRC). To deploy new materials or materials manufactured with new technologies, such as additive manufacturing, materials must be evaluated for reactor-induced degradation from the combination of harsh temperatures, corrosive environments, and radiation fields. However, rapid deployment of materials necessitates accelerated testing methods rather than relying on years of neutron irradiation in a material test reactor. Ion irradiation has demonstrated success in reproducing material microstructure and select property evolution resulting from neutron irradiation with three to four orders of magnitude reduction in time and cost, making it an ideal candidate for accelerated irradiation testing. This presentation provides context governing both the scientific and regulatory aspects of the proposed goal. The discussion is aimed at a broad audience including researchers from industry, national laboratories, and academia. The recommended path forward is presented as a conceptual framework of specific steps. In brief, the strategy entails developing an integrated ion and neutron irradiation test plan for the material property of interest based on the fundamental tenet of the linkage of microstructure and properties in materials. Physics-based modeling interprets ion irradiation data and predicts neutron irradiation microstructure and properties with uncertainty bounds. The first round of testing is sufficient for an initial licensing application using a risk-informed approach, while a minimum required neutron irradiation test plan reduces cost and time requirements. A surveillance program with witness specimens in-reactor provides additional data over time to improve model predictions to higher damage levels and further reduce uncertainty bounds, which can be used for license extensions or longer lifetimes in new license applications.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

Domain-decomposition nonlinear manifold reduced order model

This software combines nonlinear-manifold reduced order models (NM-ROMs) with domain decomposition (DD) techniques. NM-ROMs, which utilize a shallow, sparse autoencoder trained with full order model (FOM) snapshot data, approximate the FOM state on a nonlinear manifold. These models offer advantages over linear-subspace ROMs (LS-ROMs) particularly in scenarios with slowly decaying Kolmogorov n-width. However, the training of NM-ROMs involves a number of parameters that scale with the size of the FOM, and storing high-dimensional FOM snapshots can significantly increase the cost of ROM training for extreme-scale problems. To mitigate these costs, the software employs DD to partition the FOM into smaller subdomains, computes NM-ROMs for each, and then integrates these to form a global NM-ROM. This strategy offers multiple benefits: it enables parallel training of subdomain NM-ROMs, reduces the number of parameters needed, decreases the dimensional requirements of subdomain FOM training data, and allows for customization to the unique characteristics of each FOM subdomain. The use of a shallow, sparse autoencoder architecture in each subdomain NM-ROM facilitates the application of hyper-reduction (HR), simplifying the nonlinear complexities and enhancing computational speed. This software marks the inaugural application of NM-ROM combined with HR to a DD problem. It features an algebraic DD reformulation of the FOM, training of NM-ROMs with HR for each subdomain, and employs a sequential quadratic programming (SQP) solver for the evaluation of the coupled global NMROM. The effectiveness of the DD NM-ROM with HR is numerically demonstrated on the 2D steady-state Burgers' equation, showing an order of magnitude improvement in accuracy over the DD LS-ROM with HR.

Diaz, AlejandroN↗

Finite-rate entrainment effects on nitrogen oxide (NO x ) emissions in staged combustors

Axially staged combustors offer the potential for achieving low NO x emissions from gas turbines at the elevated temperatures required to achieve at least 65% combined cycle efficiencies. While there is evidence that premixing between the main burner products and secondary stream reduces NO x , it is important to characterize the specific requirements needed to achieve low emissions at gas turbine conditions. This study examines the sensitivity of NO x to finite-rate, large-scale entrainment of the main and secondary streams under the simplifying assumption of infinitely-fast small-scale mixing. Essentially, this allows us to isolate the effects of limited large-scale entrainment rates by using a homogeneous/uniform condition for the entrained and reacting gases. We use a reduced-order reactor network model to examine a generic staged-combustor whose inputs are physical time scales that embody the finite-rate entrainment characteristics. With simulations conducted over a large parameter space at typical operating conditions (25 atm, 650 K air), the results show that, even when small-scale mixing is infinitely fast and the reaction zone is uniform, entrainment significantly affects NO x emissions due to its influence on the equivalence ratio — and thus the temperature and time — at which the entrained mixture ignites. Fuel-air staging is shown to be vital to NO x reduction in most practical cases where entrainment times exceed roughly 1 ms and the secondary stream finishes entraining before the main burner products. A constrained NO x minimization indicates that using the leanest possible main burner and re-routing as much air as possible to the secondary stage is key to low NO x with finite-rate entrainment; for example, less than 10 ppm NO x can be achieved if the secondary stage contains 20% of the total mass flow.

03 NATURAL GAS↗

Embedded shear layer computations for increased drag reduction

One of the most promising methods of minimizing drag is the reduction of skin friction by injection of low momentum fluid into the near-wall region of turbulent boundary layer flows. This method could be made more effective by limiting the spread rate of the resulting mixing region. In order to achieve a better understanding of how this goal might be achieved, numerical investigations of the relevant fluid dynamic processes governing these regions have been conducted. A compact finite-difference algorithm has been applied to the complete form of the governing conservation equations for a two-dimensional laminar mixing layer. The ability of this computational approach to model successfully the formation and interaction of the large scale vortical structures which dominate such flow fields is verified in the present study. Parameters which affect the spread rate of the mixing region are also identified. In addition, the relative importance of viscous and momentum transport effects in the vortex interactions is determined.

Gatski, T. B.↗

Moisture Forecast Bias Correction in GEOS DAS

Data assimilation methods rely on numerous assumptions about the errors involved in measuring and forecasting atmospheric fields. One of the more disturbing of these is that short-term model forecasts are assumed to be unbiased. In case of atmospheric moisture, for example, observational evidence shows that the systematic component of errors in forecasts and analyses is often of the same order of magnitude as the random component. we have implemented a sequential algorithm for estimating forecast moisture bias from rawinsonde data in the Goddard Earth Observing System Data Assimilation System (GEOS DAS). The algorithm is designed to remove the systematic component of analysis errors and can be easily incorporated in an existing statistical data assimilation system. We will present results of initial experiments that show a significant reduction of bias in the GEOS DAS moisture analyses.

Dee, D.↗

Lunar Surface Stirling Power Systems Using Isotope Heat Sources

For many years, NASA has used the decay of plutonium-238 (Pu-238) (in the form of the General Purpose Heat Source (GPHS)) as a heat source for Radioisotope Thermoelectric Generators (RTGs), which have provided electrical power for many NASA missions. While RTGs have an impressive reliability record for the missions in which they have been used, their relatively low thermal to electric conversion efficiency and the scarcity of plutonium-238 (Pu-238) has led NASA to consider other power conversion technologies. NASA is considering returning both robotic and human missions to the lunar surface and, because of the long lunar nights (14.75 Earth days), isotope power systems are an attractive candidate to generate electrical power. NASA is currently developing the Advanced Stirling Radioisotope Generator (ASRG) as a candidate higher efficiency power system that produces greater than 160 W with two GPHS modules at the beginning of life (BOL) (~32% efficiency). The ASRG uses the same Pu-238 GPHS modules, which are used in RTG, but by coupling them to a Stirling convertor provides a four-fold reduction in the number of GPHS modules. This study considers the use of americium-241 (Am-241) as a substitute for the Pu-238 in Stirling- convertor-based Radioisotope Power Systems (RPS) for power levels from tens of watts to 5 kWe. The Am-241 is used as a substitute for the Pu-238 in GPHS modules. Depending on power level, different Stirling heat input and removal systems are modeled. It was found that substituting Am-241 GPHS modules into the ASRG reduces power output by about one-fifth while maintaining approximately the same system mass. In order to obtain the nominal 160 W of electrical output of the Pu-238 ASRG requires 10 Am-241 GPHS modules. Higher power systems require changing from conductive coupling heat input and removal from the Stirling convertor to either pumped loops or heat pipes. Liquid metal pumped loops are considered as the primary heat transportation on the hot end and water pumped loop/heat pipe radiator is considered for the heat rejection side for power levels above 1 kWe.

Schmitz, Paul C.↗

Planetary Suit Hip Bearing Model for Predicting Design vs. Performance

Designing a planetary suit is very complex and often requires difficult trade-offs between performance, cost, mass, and system complexity. In order to verifying that new suit designs meet requirements, full prototypes must eventually be built and tested with human subjects. Using computer models early in the design phase of new hardware development can be advantageous, allowing virtual prototyping to take place. Having easily modifiable models of the suit hard sections may reduce the time it takes to make changes to the hardware designs and then to understand their impact on suit and human performance. A virtual design environment gives designers the ability to think outside the box and exhaust design possibilities before building and testing physical prototypes with human subjects. Reductions in prototyping and testing may eventually reduce development costs. This study is an attempt to develop computer models of the hard components of the suit with known physical characteristics, supplemented with human subject performance data. Objectives: The primary objective was to develop an articulating solid model of the Mark III hip bearings to be used for evaluating suit design performance of the hip joint. Methods: Solid models of a planetary prototype (Mark III) suit s hip bearings and brief section were reverse-engineered from the prototype. The performance of the models was then compared by evaluating the mobility performance differences between the nominal hardware configuration and hardware modifications. This was accomplished by gathering data from specific suited tasks. Subjects performed maximum flexion and abduction tasks while in a nominal suit bearing configuration and in three off-nominal configurations. Performance data for the hip were recorded using state-of-the-art motion capture technology. Results: The results demonstrate that solid models of planetary suit hard segments for use as a performance design tool is feasible. From a general trend perspective, the suited performance trends were comparable between the model and the suited subjects. With the three off-nominal bearing configurations compared to the nominal bearing configurations, human subjects showed decreases in hip flexion of 64%, 6%, and 13% and in hip abduction of 59%, 2%, and 20%. Likewise the solid model showed decreases in hip flexion of 58%, 1%, and 25% and in hip abduction of 56%, 0%, and 30%, under the same condition changes from the nominal configuration. Differences seen between the model predictions and the human subject performance data could be attributed to the model lacking dynamic elements and performing kinematic analysis only, the level of fit of the subjects with the suit, the levels of the subject s suit experience.

Cowley, Matthew S.↗

Changes in Tropical Clouds and Atmospheric Circulation Associated with Rapid Adjustment Induced by Increased Atmospheric CO2 – A Multiscale Modeling Framework Study

The radiative heating increase due to increased CO2 concentration is the primary source for the rapid adjustment of atmospheric circulation and clouds. In this study, we investigate the rapid adjustment resulting from doubling of CO2 and its physical mechanism using a multiscale modeling framework (MMF). The MMF includes an advanced higher-order turbulence closure in its cloud-resolving model component and simulates realistic shallow and deep cloud climatology and boundary layer turbulence. The rapid adjustment over the tropics is characterized by 1) reduced ascent and descent strengths over the ocean, 2) increased lower tropospheric stability (LTS) over the subsidence region, 3) shoaling of planetary boundary layers over the ocean, 4) increased deep convection over lands and shift of cloud coverage from the ocean to lands, and 5) reduced sensible (SH) and latent heat (LH) fluxes over the oceanic deep convective regions. Unlike conventional general circulation models and another MMF, a reduction in the global-mean shortwave cloud radiative cooling is not simulated, due to the increase in low clouds at lower altitudes over the ocean, resulting from reduced cloud-top entrainment due to strengthened inversion. Changes in regional circulation play a key role in cloud changes and shift of cloud coverage to lands. Weaker energy transport resulting from water vapor and cloud CO2 masking effects reduces the upward motion and convective clouds in the oceanic regions. The ocean-land transports are linked to the partitioning of surface SH and LH fluxes that increases humidity over lands and enhances deep convection over the tropical lands.

Xu, Kuan-Man↗

Experimental studies of collision and fragmentation phenomena

The reduction and publication of an extensive data set collected in experiments over several years at Ames and PSI is briefly examined. Hartmann has been assembling data sets from his experiments on catastrophic fragmentation of various materials, including basalt, other igneous rock, ice, and weak dirt clods. Weidenschilling and Davis have continued to gather and reduce data on oblique impacts. The data indicate a power law distribution of ejecta mass vs. velocity, with a slope that is independent of azimuth, and does not vary with impact angle from normal impacts to at least 75 deg from vertical. In order to improve models of coagulation of dust aggregates in the solar nebula, SJW developed an apparatus for drop tests of fragile projectiles. Davis and Weidenschilling continued to collect and analyze experimental data on collisional catastrophic disruption at the Ames Vertical Gun Range.

Hartmann, William K.↗

Reduced Stress Tensor and Dissipation and the Transport of Lamb Vector

We develop a methodology to ensure that the stress tensor, regardless of its number of independent components, can be reduced to an exactly equivalent one which has the same number of independent components as the surface force. It is applicable to the momentum balance if the shear viscosity is constant. A direct application of this method to the energy balance also leads to a reduction of the dissipation rate of kinetic energy. Following this procedure, significant saving in analysis and computation may be achieved. For turbulent flows, this strategy immediately implies that a given Reynolds stress model can always be replaced by a reduced one before putting it into computation. Furthermore, we show how the modeling of Reynolds stress tensor can be reduced to that of the mean turbulent Lamb vector alone, which is much simpler. As a first step of this alternative modeling development, we derive the governing equations for the Lamb vector and its square. These equations form a basis of new second-order closure schemes and, we believe, should be favorably compared to that of traditional Reynolds stress transport equation.

Wu, Jie-Zhi↗

Model-size reduction technique for the analysis of symmetric anisotropic structures

A two-step computational procedure is presented for reducing the size of the analysis model for an anisotropic symmetric structure to that of the corresponding orthotropic structure. The key elements of the procedure are: (1) decomposition of the stiffness matrix into the sum of an orthotropic and nonorthotropic (anisotropic) parts; and (2) successive application of the finite element method and the classical Rayleigh-Ritz technique. The finite element method is first used to generate few global approximation vectors (or modes). Then the amplitudes of these modes are computed by using the Rayleigh-Ritz technique. The global approximation vectors are selected to be the solution corresponding to zero nonorthotropic matrix and its various-order derivatives with respect to an anisotropic tracing parameter (identifying the nonorthotropic material coefficients). The size of the analysis model used in generating the global approximation vectors is identical to that of the corresponding orthotropic structure. The effectiveness of the proposed technique is demonstrated by means of numerical examples and its potential for solving other quasi-symmetric problems is discussed.

Noor, A. K.↗

Challenging conventional assumptions in PV: a high-throughput open-air approach to low-cost perovskite module production

Perovskite solar modules (PSMs) offer a promising pathway to low-cost photovoltaics, yet their commercialization is challenged by manufacturing scalability, device uniformity, additive costs, interlayer complexity, and module stability. This study introduces a comprehensive technoeconomic analysis of single junction PSM's and projections for tandem perovskite-Si modules that integrate all materials and manufacturing steps, module performances, projected lifetimes, and manufacturing costs across scales. Here, we highlight an open-air manufacturing approach to fabricate all active layers of serially interconnected PSMs, including electrodes and charge transport layers, enabling high-throughput production without inert or vacuum environments. The analysis reveals two orders of magnitude throughput enhancement and cost reductions of 24% in all-open-air production, escalating to over 60% at 1 GW factory capacity compared to conventional methods. Levelized cost of energy (LCOE) projections for utility-scale installations over 30 years, accounting for module replacement and recycling, demonstrate the potential to achieve the 2030 US target of $0.03 per kWh with realistic 7–11-year PSM lifetimes, outperforming incumbent silicon-based modules. Neither four terminal (4T) nor two terminal (2T) tandem-Si PSMs improve over single junction perovskite or silicon LCOE regardless of higher efficiencies at any modeled lifetime. Addressing PSM technical challenges with a cost-modeling framework guides commercialization efforts and provides a convincing pathway for challenging incumbent Si-based PV.

14 SOLAR ENERGY↗