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DOE OSTI2020

Physically Based Modeling of PEMFC Cathode Catalyst Layers: Effective Microstructure and Ionomer Structure–Property Relationship Impacts

Abstract This work presents a pseudo-two-dimensional proton exchange membrane fuel cell (PEMFC) model incorporating Nafion ionomer structure–property relationships in the cathode catalyst layer (CL) to capture and explain losses at low Pt loading. Structural data from neutron reflectometry and thin film Nafion conductivity measurements predict variations in the oxygen diffusion coefficient and ionic conductivity with changing CL ionomer thickness and Pt loading. By including these structure–property relationships, predicted polarization curves agree closely with previously published experimental data from cells with Pt loadings between 0.025 and 0.2 mg/cm2. Results demonstrate that structure–property relationships based on physically measurable ionomer and CL properties provide a feasible interpretation of PEMFC CL phenomena for a range of Pt loadings and help explain previously unaccounted-for losses at low Pt. Results also show that simulations must account for surface species coverage variations in order to properly capture the kinetic losses. Finally, results suggest that an increase in ionomer thickness surrounding the C/Pt surfaces may lead to improved cell performance due to improved ionic conductivity.

Electrochemistry↗

DOE OSTI2024

Binary pseudo-random array standards for calibration of 3D optical surface profilers used for metrology with significantly curved x-ray optics

High-accuracy metrology is vitally important in manufacturing ultra-high-quality free-form mirrors designed to manipulate X-ray light with nanometer-scale wavelengths. The current capabilities and possibility for improvements in X-ray mirror manufacturing are limited by inherent imperfections of the integrated metrology tools. In the case of Fizeau interferometry, metrology tools are currently calibrated with super-polished flat test-standard/reference mirrors. This is acceptable for measuring slightly curved X-ray optics. However, for even moderately curved aspherical X-ray mirrors the flat-reference calibration is not sufficiently accurate and stitching Fizeau interferometer-based surface metrology is used to mitigate the problem. But still, the retrace and aberration errors, as well as the limited spatial resolution, described with the instrument transfer function (ITF), can be transferred into the optical surface topography of X-ray mirrors obtained in stitching metrology. For ITF calibration, we have developed an original technique, based on test standards structured as two-dimensional (2D) highly-randomized (HR) binary pseudo-random arrays (BPRAs). The technique employs the unique properties of the HR BPRA patterns in the spatial frequency domain., i.e. the inherent 2D power spectral density of the HR BPRA pattern has a deterministic white-noise-like character that allows direct determination of the ITF with uniform sensitivity over the entire spatial frequency range and field-of-view of an instrument. Here, we explore technological, metrological, and analytical aspects essential for calibration of the retrace and aberration errors of Fizeau interferometers using different types of tilted test samples, including a super-polished reference mirror for the re-trace calibration and the uniformly redundant array (URA) BPRA standards for the geometrical distortion (aberration) calibration. While the first method was previously demonstrated by researchers at DIAMOND Light Source, a method based on the URA BPRA is described and demonstrated here for the first time. We outline the design and fabrication process used in fabrication of URA BPRA test standards, and present the results of application of the URA BPRA standards demonstrating the high efficacy of our approach to geometrical distortion calibration of Fizeau interferometers. We also discuss the possible sources of unexpected peculiarities of the systematic errors, including an astigmatic character of the retrace error, observed with Fizeau interferometers at the Advanced Light Source X-Ray Optics Laboratory.

Munechika, Keiko↗

DOE OSTI2025

Discovering Dark Matter with the MUonE Experiment

The MUonE experiment aims to extract the hadronic contribution to the muon anomalous magnetic moment from a precise measurement of the muon-electron differential scattering cross section. We show that MUonE can also discover thermal relic dark matter using only its nominal experimental setup. Our search strategy is sensitive to models of dark matter in which pairs of pseudo-Dirac fermions are produced in muon-nucleus scattering in the target, and the heavier state decays semivisibly to yield dilepton pairs displaced downstream from the interaction point. This approach can probe sub-GeV thermal-relic dark matter whose cosmological abundance is governed by the same model parameters that set the MUonE signal strength. Furthermore, our results show that the downstream electron calorimeter plays a key role in rejecting backgrounds for this search, thereby providing strong motivation for the MUonE to keep this component in the final experimental design. Published by the American Physical Society 2025

72 PHYSICS OF ELEMENTARY PARTICLES AND FIELDS↗

DOE OSTI2020

Neutrinoless double beta decay versus other probes of heavy sterile neutrinos

We make a comparative study of the neutrinoless double beta decay constraints on heavy sterile neutrinos versus other direct and indirect constraints from both lepton number conserving and violating processes, as a sensitive probe of the extent of lepton number violation and possible interference effects in the sterile sector. We introduce a phenomenological parametrisation of the simplified one-generation seesaw model with one active and two sterile neutrino states in terms of experimentally measurable quantities, such as active-sterile neutrino mixing angles, CP phases, masses and mass splittings. This simple parametrisation enables us to analytically derive a spectrum of possible scenarios between the canonical seesaw with purely Majorana heavy neutrinos and inverse seesaw with pseudo-Dirac ones. We then go on to constrain the simplified parameters of this model from various experiments at the energy, intensity and cosmic frontiers. We emphasise that the constraints from lepton number violating processes strongly depend on the mass splitting between the two sterile states and the relative CP phase between them. This is particularly relevant for neutrinoless double beta decay, which is weakened for small mass splitting and opposite CP parities between the sterile states. On the other hand, neutrinoless double beta decay is especially sensitive for Majorana sterile neutrinos with masses around 0.1-10 GeV.

71 CLASSICAL AND QUANTUM MECHANICS, GENERAL PHYSIC↗

DOE OSTI2023

Phase Heterogeneity in Cholesterol-Containing Ternary Phospholipid Lamellar Phases

Pseudo-ternary mixtures of lamellar phase phospholipids (DPPC and brain sphingomyelin with cholesterol) were studied below T m while comparing the influence of cholesterol content, temperature, and the presence of small quantities of vitamin D binding protein (DBP) or vitamin D receptor (VDR). The measurements, conducted by X-ray diffraction (XRD) and nuclear magnetic resonance (NMR), cover a range of cholesterol concentrations (20% mol. wt to 40% mol. wt.) and physiologically relevant temperature range (294–314 K). In addition to rich intraphase behavior, data and modeling are used to approximate the lipids’ headgroup location variations under the abovementioned experimental conditions.

36 MATERIALS SCIENCE↗

DOE OSTI2023

Atomistic insight into the ferroelastic post-stishovite transition by high-pressure single-crystal X-ray diffraction

Abstract The post-stishovite transition is a classic pseudo-proper typed ferroelastic transition with a symmetry-breaking spontaneous strain. This transition has been studied using high-pressure spontaneous strains, optic modes, and elastic moduli (Cij) based on the Landau modeling, but its atomistic information and structural distortion remain poorly understood. Here we have conducted synchrotron single-crystal X-ray diffraction measurements on stishovite crystals up to 75.3 GPa in a diamond-anvil cell. Analysis of the data reveals atomic positions, bond lengths, bond angles, and variations of SiO6 octahedra across the transition at high pressure. Our results show that the O coordinates split at ~51.4 GPa, where the apical and equatorial Si-O bond lengths cross over, the SiO6 octahedral distortion vanishes, and the SiO6 octahedra start to rotate about the c axis. Moreover, distortion mode analysis shows that an in-plane stretching distortion (GM1+ mode) occurs in the stishovite structure at high pressure while a rotational distortion (GM2+ mode) becomes dominant in the post-stishovite structure. These results are used to correlate with elastic moduli and Landau parameters (symmetry-breaking strain e1–e2 and order parameter Q) to provide atomistic insight into the ferroelastic transition. When the bond lengths of two Si-O bonds are equal due to the contribution from the GM1+ stretching mode, C11 converges with C12, and the shear wave VS1[110] polarizing along [110] and propagating along [110] vanishes. Values of e1–e2 and Q are proportional to the SiO6 rotation angle from the occurrence of the GM1+ rotational mode in the post-stishovite structure. Our results on the pseudo-proper type transition are also compared with that for the proper type in albite and improper type in CaSiO3 perovskite. The symmetry-breaking strain, in all these types of transitions, arises as the primary effect from the structural angle (such as SiO6 rotation or lattice constant angle) and its relevant distortion mode in the low-symmetry ferroelastic phase.

Geochemistry & Geophysics↗

DOE OSTI2020

Multiplicity and pseudo-rapidity density distributions of charged particles produced in pp, pA and AA collisions at RHIC & LHC energies

Multiplicity and pseudorapidity (η) density (d N ch /dη) distributions of charged hadrons provide key information towards understanding the particle production mechanisms and initial conditions of high-energy heavy-ion collisions. However, detector constraints limit the η-range across which charged particle measurements can be carried out. Extrapolating the measured distributions to large η-range by parameterizing measured distributions and by using calculations from event generators, we characterize the production of charged particles over the full kinematic range. In the present study, we use three different ansätze to obtain quantitative descriptions of the shape of pseudorapidity distributions of charged hadrons produced in pp, p–A, and A–A collisions for beam energies ( s NN ) ranging from a few GeV to a few TeV corresponding to RHIC and LHC energies. We study the limiting fragmentation behavior in these collisions and report evidence for participant-scaling violations in high-energy collisions at the TeV scale. We additionally examine measured pseudorapidity distributions to constrain models describing initial conditions of particle production. We predict the centrality dependence of charged particle multiplicity distributions at FAIR and NICA energies and give an estimation of charged particle multiplicity at η = 0 for the proposed HE-LHC and FCC energies.

Physics↗

DOE OSTI2023

Structure and Magnetic Properties of Pseudo-1D Chromium Thiolate Coordination Polymers

The synthesis, structure, and magnetic properties of two novel, pseudo-one-dimensional (1D) chromium thiolate coordination polymers (CPs), CrBTT and Cr2BDT3, are reported. The structures of these materials were determined using X-ray powder diffraction revealing highly symmetric 1D chains embedded within a CP framework. The magnetic coupling of this chain system was measured by SQUID magnetometry, revealing a switch from antiferromagnetic to ferromagnetic behavior dictated by the angular geometrical constraints within the CP scaffold consistent with the Goodenough–Kanamori–Anderson rules. Intrachain magnetic coupling constants J NN of –32.0 and +5.7 K were found for CrBTT and Cr 2 BDT 3 , respectively, using the 1D Bonner–Fisher model of magnetism. The band structure of these materials has also been examined by optical spectroscopy and density functional theory calculations revealing semiconducting behavior. Furthermore, our findings here demonstrate how CP scaffolds can support idealized low-dimensional structural motifs and dictate magnetic interactions through tuning of geometry and inter-spin couplings.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2026

Testing thermal-relic dark matter with a dark-photon mediator

In light of recent DAMIC-M results, we present the status of thermal-relic dark matter χ coupled to a kinetically mixed dark photon A ′ . In the predictive “direct annihilation” regime, m A ′ > m χ , the relic abundance depends on the kinetic mixing parameter, and there is a minimum value compatible with thermal freeze-out. Using only electron- and nuclear-recoil direct-detection results, we find that, for complex scalar dark matter, the direct annihilation regime is now excluded for nearly all values of m χ ; the only exception is the resonant annihilation regime where m A ′ ≈ 2 m χ . Direct annihilation relic targets for other representative models, including Majorana and pseudo-Dirac candidates, remain viable across a wide range of model parameters but will be tested with a combination of dedicated accelerator searches in the near future. In the opposite “secluded annihilation” regime, where m χ > m A ′ , this scenario is excluded by cosmic microwave background measurements for all m χ ≲ 30 GeV . Similar conclusions in both the direct and secluded regimes hold for all anomaly-free vector mediators that couple to the first generation of electrically charged Standard Model particles.

Krnjaic, Gordan [Fermilab; Chicago U., KICP] (ORCI↗

DOE OSTI2023

Pseudorandomness from Subset States

We show it is possible to obtain quantum pseudorandomness and pseudoentanglement from random subset states -- i.e. quantum states which are equal superpositions over (pseudo)random subsets of strings. This answers an open question of Aaronson et al. [arXiv:2211.00747], who devised a similar construction augmented by pseudorandom phases. Our result follows from a direct calculation of the trace distance between t copies of random subset states and the Haar measure, via the representation theory of the symmetric group. We show that the trace distance is negligibly small, as long as the subsets are of an appropriate size which is neither too big nor too small. In particular, we analyze the action of basis permutations on the symmetric subspace, and show that the largest component is described by the Johnson scheme: the double-cosets of the symmetric group S N by the subgroup S t x S N-t . The Gelfand pair property of this setting implies that the matrix eigenbasis coincides with the symmetric group irreducible blocks, with the largest eigenblock asymptotically approaching the Haar average. An immediate corollary of our result is that quantum pseudorandom and pseudoentangled state ensembles do not require relative phases.

Computational Complexity (cs.CC)↗

DOE OSTI2021

Neural network for 3D inertial confinement fusion shell reconstruction from single radiographs

In inertial confinement fusion (ICF), x-ray radiography is a critical diagnostic for measuring implosion dynamics, which contain rich three-dimensional (3D) information. Traditional methods for reconstructing 3D volumes from 2D radiographs, such as filtered backprojection, require radiographs from at least two different angles or lines of sight (LOS). In ICF experiments, the space for diagnostics is limited, and cameras that can operate on fast timescales are expensive to implement, limiting the number of projections that can be acquired. To improve the imaging quality as a result of this limitation, convolutional neural networks (CNNs) have recently been shown to be capable of producing 3D models from visible light images or medical x-ray images rendered by volumetric computed tomography. Here, we propose a CNN to reconstruct 3D ICF spherical shells from single radiographs. We also examine the sensitivity of the 3D reconstruction to different illumination models using preprocessing techniques such as pseudo-flatfielding. To resolve the issue of the lack of 3D supervision, we show that training the CNN utilizing synthetic radiographs produced by known simulation methods allows for reconstruction of experimental data as long as the experimental data are similar to the synthetic data. We also show that the CNN allows for 3D reconstruction of shells that possess low mode asymmetries. Further comparisons of the 3D reconstructions with direct multiple LOS measurements are justified.

3D Reconstruction↗

DOE OSTI2021

Stars in the local galactic thick disc and halo in Gaia EDR3: a catalogue of half a million local main-sequence stars with photometric metallicities

We present a catalogue of 551 214 main-sequence stars in the local (d < 2 kpc) Galactic thick disc and halo, based on a search of stars with large proper motions ($\mu _{\rm tot} \gt 40.0~\rm mas\, yr^{-1}$) in the Gaia Early Data Release 3. We derive photometric metallicity calibrated from the colour–luminosity–metallicity distribution of 20 047 stars with spectroscopic metallicities, collected from various spectroscopic surveys, including SDSS SEGUE/APOGEE, GALAH DR3, and LAMOST DR6. We combine these results to construct an empirical colour–magnitude–metallicity grid, which can be used to estimate photometric metallicities for low-mass metal-poor stars of K and M subtypes from their absolute G magnitude and colour values. We find that low-mass, high-velocity stars in our catalogue share similar kinematics as reported in recent studies of more luminous Galactic halo stars. The pseudo-kinematic analysis of our sample recovers the main local halo structures, including the Gaia–Enceladus Stream and the Helmi stream; aside from these, the local halo stars appear to show a remarkably smooth distribution in velocity space. Since the future Gaia data release will provide radial velocity measurements for only a small number of our sample, our catalogue provides targets of high interest for the future spectroscopic observation programs.

79 ASTRONOMY AND ASTROPHYSICS↗

DOE OSTI2022

Constraints on Higgs boson properties using $WW^*(→eνμν)jj$ production in 36.1fb -1 of $\sqrt{s}$ = 13 TeV pp collisions with the ATLAS detector

This article presents the results of two studies of Higgs boson properties using the WW * (→eνμν)jj final state, based on a dataset corresponding to 36.1fb -1 of $\sqrt{s}$ =13 TeV proton–proton collisions recorded by the ATLAS experiment at the Large Hadron Collider. The first study targets Higgs boson production via gluon–gluon fusion and constrains the CP properties of the effective Higgs–gluon interaction. Using angular distributions and the overall rate, a value of tan(α)=0.0±0.4(stat.)±0.3(syst.) is obtained for the tangent of the mixing angle for CP-even and CP-odd contributions. The second study exploits the vector-boson fusion production mechanism to probe the Higgs boson couplings to longitudinally and transversely polarised W and Z bosons in both the production and the decay of the Higgs boson; these couplings have not been directly constrained previously. The polarisation-dependent coupling-strength scale factors are defined as the ratios of the measured polarisation-dependent coupling strengths to those predicted by the Standard Model, and are determined using rate and kinematic information to be a L =0.91$^{+0.10}_{-0.18}$(stat.)$^{+0.09}_{-0.17}$(syst.) and a T =1.2±0.4(stat.)$^{+0.2}_{-0.3}$(syst.). These coupling strengths are translated into pseudo-observables, resulting in κ VV =0.91$^{+0.10}_{-0.18}$(stat.)$^{+0.09}_{-0.17}$(syst.) and ϵ VV =0.13$^{+0.28}_{-0.20}$ (stat.)$^{+0.08}_{-0.10}$(syst.). All results are consistent with the Standard Model predictions.

72 PHYSICS OF ELEMENTARY PARTICLES AND FIELDS↗

DOE OSTI2021

Suggestions on the Vapor Pressure Determination of Molten Salts

The knowledge of the thermophysical properties of coolant and fuel in molten salts nuclear reactors (MSRs), such as thermal stability and vapor pressure, are of remarkable interest, particularly for simulating safe reactor operations. Molten salt reactorsMSRs use molten salt mixtures as the primary coolant and/or fuel and are expected to operate up to 800 °C. With the revival of interest in deploying MSRs, complete thermophysical and thermochemical characterization of these materials is of interest to industry, regulators, and researchers. Vapor pressure data for molten salts are scarce in the literature, both for pure salts but especially for eutectic mixtures. This report describes the effusion method, which consist of measuring the rate of escape of vapor molecules through a small orifice for the determination of the vapor pressure of compounds and may be useful on compounds such as molten salts. Thermogravimetric analysis records the mass loss as a function of time and temperature. There are two equations that can be used to relate the mass loss rate with the vapor pressure: (1) the Knudsen equation and (2) the Langmuir equation. To apply these equations, the system needs to reach a pseudo (or near) equilibrium condition. Therefore, the experimental conditions must be such that allow the condensed and the vapor/gas phases to be in equilibrium. In order to accomplish equilibrium like conditions, the sample must be in an almost-sealed cell except for a small orifice, from where the vapor escapes. In the Knudsen method vacuum is applied to eliminate the effect that the presence of other gas molecules could have on the evaporation rate of the sample. However, Langmuir alleged that in certain conditions, such as at low temperatures and/or when the vapor pressure is low, the rate of evaporation of a substance is independent of the presence of vapor around it. For that reason, some researchers, when measuring the mass loss of a substance with a predictable low vapor pressure, do not apply vacuum when using the Langmuir equation. However, they use a standard substance to parameterize the experimental setup. The use of one equation or the other will depend on the characteristics of the sample and the availability of an appropriate standard. Some important aspects related to the nature of the samples and vapor pressure measurements are described for future consideration.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2025

Neural network-based classification and regression of magnetohydrodynamic modes in tokamaks

We present a machine learning-based magnetohydrodynamic (MHD) classifier and regressor that utilizes real or complex-valued 3D magnetic sensor array data to determine neoclassical tearing mode (NTM) onset times in tokamaks with millisecond accuracy. The input dataset consists of poloidal profiles of complex Fourier amplitudes with an n = 1 toroidal mode number from 144 human-labeled ITER Baseline Scenario discharges in the DIII-D tokamak, spanning both tearing-dominated and sawtooth-dominated regimes. Since m, n = 2,1 NTMs frequently emerge alongside sawteeth at the same frequency in this scenario, the focus is on isolating the m = 1 and m = 2 components of the n = 1 MHD mode near the tearing onset. To improve model regularization and prediction stability, singular value decomposition was applied to balance the sawtooth and tearing datasets. The enriched datasets facilitated training neural networks that learn the key distinguishing features of sawtooth and tearing modes in the poloidal profiles of their magnetic amplitude and phase. When the modes occur independently, the networks achieve perfect classification due to the modes’ distinct characteristics and low measurement noise. In the more experimentally relevant case where both modes coexist, the networks maintain exceptional performance across key metrics. Tests on synthetic data with known ground truth demonstrate the superior accuracy of the neural network trained on complex-valued input compared to models using real amplitude, phase, or pseudo-complex data, achieving both a mean time delay and standard deviation below 1 ms. Notably, standard linear regression methods fitting the dominant singular modes to the data closely match the neural network’s performance. Applying these methods across a broad range of H-mode scenarios will enable future studies to systematically identify dominant NTM triggers as scenario-specific variables, paving the way for more effective tearing mode avoidance strategies in future fusion reactor designs.

machine learning↗

DOE OSTI2021

Spent Crystalline Silicotitanate Storage Study—Post AP-105DF Processing

A Tank-Side Cesium Removal (TSCR) system is under development by Washington River Protection Solutions to support initial production of immobilized low-activity waste (LAW) by feeding Hanford tank supernate from tank farms to the Hanford Waste Treatment and Immobilization Plant (WTP) LAW Facility. Tank waste supernate will be filtered to remove suspended solids and then Cs will be removed by processing it through crystalline silicotitanate (CST) ion exchange media manufactured by Honeywell UOP, LLC. The Cs-loaded CST columns will be stored indefinitely, with a goal of eventual CST removal and treatment. Thus, the spent CST needs to be recoverable after undetermined storage time. Previous testing with AP-105 simulant showed that rinsing the CST bed with 3 bed volumes (1.4 apparatus volumes [AVs]) of 0.1 M NaOH resulted in a dried bed that maintained flow characteristics indicative of ease of recovery. This study explored the intermediate conditions (between feed dried in place and the 1.4 AVs of 0.1 M NaOH rinse) to evaluate CST bed properties after: 1) stoppage with feed in place; 2) stoppage after draining feed; 3) stoppage after 0.7 AV of 0.1 M NaOH rinse through column; 4) stoppage after 1.5 AVs of 0.1 M NaOH rinse through column. Post processing, each column was heated at 50 °C for 19 days under pseudo-storage conditions to simulate the expected dried and stored CST bed conditions. Testing was conducted at the small scale (12-mL bed volume); actual, Cs-depleted, AP-105 tank waste was used as the feed. Post-dried CST bed physical properties (angle of repose and penetration depth) were measured to evaluate how CST moved and flowed. All process stop-conditions resulted in a solidified CST bed except for the final condition, 1.5 AVs of 0.1 M NaOH rinse. At this small scale, the three CST beds presented an issue for retrievability after the short storage period (19 days at 50 °C). The latter case confirmed the results from simulant testing. The testing was intended to provide a preliminary assessment of issues that may arise from desiccation of CST during storage with the indicated salt solutions in place. Since these were small-scale tests, the processing system did not scale to full scale conditions exactly; however, the tests did provide insight into the impact on the dried and stored CST bed after stopping processing at an earlier step (upset condition) than normal. These results indicate that if an upset condition occurs at TSCR, a dilute hydroxide rinse should be considered before the CST dries from internal heating.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

DOE OSTI2021

Evaluation of the rheological and electrical percolation of high‐density polyethylene/carbon black composites using mathematical models

Abstract In this work, conductive polymer composites (CPCs) of bio‐based polyethylene (BioPe) containing different concentrations of carbon black (CB) were developed. By using oscillatory rheology analysis, a Newtonian plateau was observed in BioPe, and all BioPe/CB composites had a behavior of a pseudo‐solid and that composites with volume fractions ranging from 0.24 to 0.56 presented higher viscosity, storage, and loss modulus. This suggests the formation of a percolated network and by using the power‐law models, it was observed that the electrical percolation threshold was higher than the rheological percolation threshold. The electrical conductivity was measured using the four‐point probe method and a sigmoid model was used to predict the CPCs' electrical conductivity percolation threshold. The results indicated that the four‐point probe method presented satisfactory results according to the calculated standard deviations and voltage–current characteristics for each round of measurements considering the same ranging as used in rheology analysis. The analytical model used showed a coefficient of determination ( R 2 ) higher than 95%, allowing the prediction of the electrical conductivity of the CPC and the percolation threshold as a function of the volumetric fraction of the CB.

da SiIva, Moacy P.↗

DOE OSTI2023

Screen printable copper pastes for silicon solar cells

The current work demonstrates the successful metallization of a PERC silicon solar cell with screen-printable copper (Cu) paste that is sintered at elevated temperature in air atmosphere. The existing state of the art in Silicon (Si) solar cell metallization is silver (Ag) paste; Cu cost is 1/100th the cost of Ag and has a comparable conductivity. However, Cu undergoes rapid oxidation at elevated temperatures and the high diffusion of Cu into Si restricts its usage in the metallization of silicon solar cells. In this paper, a Cu paste containing a proprietary mixture of antioxidant additives and diffusion inhibitors was used to make front gridlines on PERC cells. The Cu-printed cells were fired in an IR belt furnace with a peak temperature of 576°C in air atmosphere. The solar cells discussed here reached an efficiency of 19%, which is 88% of the efficiency measured for a commercial Ag-printed cell. The working devices were further characterized using STEM, EDX, ToF-SIMS and long-term suns-V oc studies demonstrating an absence of Cu diffusion. Furthermore, thermally stressing the Cu-printed solar cells yielded a reduction of less than 1.9% of the initial pseudo fill factor (pFF) after 1000 hours at 200°C. Here, the shunt resistance of cells monitored over 3 years remained within 2.5% of its initial value, which demonstrates the effectiveness of the Cu diffusion barrier.

14 SOLAR ENERGY↗