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DOE OSTI2024

Spectral and Temperature-Dependent Optical Metrology: Towards More Robust, Effective and Durable Materials for Concentrated Solar Power

The primary objective of this project is to develop reliable and standardized spectroscopic measurement techniques to determine radiative properties, specifically the emittance and reflectance, of materials relevant for the next generation (Gen3) concentrated solar power (CSP) technologies. Experimental measurements will span near- and mid-infrared wavelengths (1–20 µm) with emphasis on quantifying the influences of: (1) operating temperatures of 25–1000 °C, (2) thermal cycling, and (3) environmental exposure of materials during operation (vacuum/air). A secondary goal is to develop open-access and digitized databases to host and share experimental data, together with standardized measurement protocols and operating procedures to determine optical properties of materials. This project will also include reasonable emphasis on developing predictive modeling tools to augment experimental data to extract more fundamental and material-specific radiative properties.

14 SOLAR ENERGY↗

NASA NTRS1983

Carbon, oxygen and their interaction with intrinsic point defects in solar silicon ribbon material: A speculative approach

Some background information on intrinsic point defects is provided and on carbon and oxygen in silicon in so far as it may be relevant for the efficiency of solar cells fabricated from EFG ribbon material. The co-precipitation of carbon and oxygen and especially of carbon and silicon self interstitials are discussed. A simple model for the electrical activity of carbon-self-interstitial agglomerates is presented. The self-interstitial content of these agglomerates is assumed to determine their electrical activity and that both compressive stresses (high self-interstitial content) and tensile stresses (low self-interstitial content) give rise to electrical activity of the agglomerates. The self-interstitial content of these carbon-related agglomerates may be reduced by an appropriate high temperature treatment and enhanced by a supersaturation of self-interstitials generated during formation of the p-n junction of solar cells. Oxygen present in supersaturation in carbon-rich silicon may be induced to form SiO, precipitates by self-interstitials generated during phosphorus diffusion. It is proposed that the SiO2-Si interface of the precipates gives rise to a continuum of donor stables and that these interface states are responsible for at least part of the light inhancement effects observed in oxygen containing EFG silicon after phosphorus diffusion.

Goesele, U.↗

NASA NTRS1972

Effects of electrostatic rocket material deposited on solar cells.

If solar arrays on solar-electric spacecraft protrude into the exhaust hemisphere of the electric thrusters, they will receive fluxes (usually small) of both propellant and accelerator grid atoms. Unlike propellants, grid materials have low vapor pressures and will not reevaporate. An analysis is presented of degradation in the optical, thermal, and electrical performance of solar cells resulting from thin deposits of grid material (aluminum and molybdenum) on various array surfaces. The classical optical theory of thin films, heat balance equations, and a typical relationship for solar cell efficiency vs temperature are used to compute curves showing optical properties, temperature, and power output as functions of film thickness. The results compare favorably with available experimental data. It is shown that a few monolayers of metal deposition on the illuminated surface will seriously degrade cell performance. A means of estimating the arrival rate of these materials is provided.

Kemp, R. F.↗

NASA NTRS2006

Material Interactions with Solar Wind Ion Environments

Solar wind composition is dominated by hydrogen (approx.96%) and helium (approx.3 to 4%) with a minor fraction (less than or equal to 1%) of heavy ions. Hydrogen (helium) ions impact spacecraft surfaces with energies from 0.5 to 5 keV (1.8 to 21 keV) due to variations in solar wind velocity from 300 km/s to 1000 km/sec with extremes of a few 10 s keV during periods of extremely high solar wind velocity exceeding 1000 km/sec. Mean impact energies are typically on the order of approximately 1 keV and 4 keV for hydrogen ions and helium ions, respectively. These energies are typically of the peak of the energy dependent light ion sputter yields for hydrogen and helium on many metals. In addition, light ions with kilovolt energies have been shown to produce blister (or exfoliation) damage to metal surfaces due to formation of high pressure gas bubbles within the materials when exposed to ion fluences on the order of 10(exp 16 to (10(exp 17 ions/sq cm. A number of spacecraft designs for current and future missions include gossamer polymer structures with thin metallic reflection coatings to shield instruments from the Sun or solar sail propulsion systems for use in a variety of locations in the inner solar system from 0.5 to 1 AU. In addition, there is interest in designing spacecraft for solar physics missions requiring operations as close to the Sun as 0.16 to 0.2 AU. Integrity of the metallic coatings is critical in many of these applications since degradation will result in modification of material thermal properties or exposure of polymers to solar UV photons which can compromise mission requirements. This paper will evaluate the relative contributions of sputtering and blister formation to material degradation in solar wind environments over a range of radial distances from the Sun to demonstrate where solar wind environments become important for materials selection. We will first review the physics and results from laboratory measurements of light ion sputtering, blistering, and exfoliation of metallic surfaces to establish the order of magnitude ion fluence required for significant surface damage. Solar wind ion fluence environments will then be evaluated due to variations in solar wind conditions as a function of solar cycle for varying distances from the Sun using models for radial variations in solar wind ion number density, temperature, and velocity to determine where sputtering and blistering is most likely to be an issue. Finally, ion fluence statistics for varying radial distances from the Sun will be shown to establish the mission duration and radial distances from the Sun where missions will encounter sufficient ion fluence to exhibit damage to metallic surfaces.

Minow, Joseph I.↗

DOE OSTI2021

A Circular Economy for Solar Photovoltaic System Materials: Drivers, Barriers, Enablers, and U.S. Policy Considerations

As PV capacity increases, owners are also decommissioning older system assets. Estimates based on a 30-year lifetime assumption found that cumulative U.S. end-of-life (EoL) PV modules could total one million metric tons (Mt) by 2030 and up to 10 million Mt by 2050 (Weckend, Wade, and Heath 2016). Beyond maintenance replacements, early retirements that are due to efficiency upgrades and extreme weather, as well as PV deployment beyond earlier expectations, would increase these projections. PV system owners must evaluate equipment management options for used modules and system components retired during maintenance activities, refurbishment, repowering and system decommissioning. PV manufacturers must also evaluate material management options from customer returns, defects, and scrap. Management options for early retired and EoL PV system material include reuse, repair for reuse, recycling-based resource recovery, storage, and disposal. Disposal of PV system material increases the burden on landfill capacity, while reuse, repair for reuse, and recycling-based resource recovery (reuse/repair/recovery) options salvage valuable materials and provide secondary market opportunities and ancillary benefits (Weckend, Wade, and Heath 2016; EPA 2019c; SWEEP 2019). PV system owners may also decide store used modules and components as spares, or in the interim before a reuse or EoL management decision is made. Despite potential secondary market opportunities and the potential benefits associated with the repair/reuse/recovery of PV system material, anecdotal evidence suggests that in the United States decommissioned PV modules are stored, landfilled or otherwise disposed of (Salim et al. 2019; CPUC 2019b; DTSC 2019b; NREL 2019a). Some modules are being disposed of in municipal nonhazardous landfills and federally regulated hazardous treatment, storage, and disposal facilities, and others are being stored in warehouses until economically viable repair/reuse/recycling becomes available (CPUC 2019b; DTSC 2019b; NREL 2019a; Libby and Shaw 2018). As awareness of current practices grows, and the demand for critical PV module material increases, U.S. industry stakeholders, regulators, and policymakers are starting to (1) consider solutions to drive and enable environmentally sustainable materials management decisions and behaviors and (2) identify barriers to a circular economy for PV system materials. Circular economy principles attempt to transition from a "take-make-consume-dispose" linear economic system to a circular system that allows for the long life, and the reuse/repair/recovery of products and materials (Ellen MacArthur Foundation 2020). We begin this report by summarizing the drivers, barriers, and enablers to a circular economy for PV system materials in the United States. We then report on our analysis of federal and state regulatory considerations that may impact the repair/reuse/recovery of PV materials, and potential civil and criminal liabilities associated with noncompliance. We then discuss state policies and initiatives in the United States that expressly address PV system decommissioning and repair/reuse/recovery of PV materials. We conclude by providing case studies of U.S. business models for the repair/reuse/recovery of PV system materials. Our results are based on legal and literature-based research and interviews with solar industry stakeholders, regulators, and policymakers.

14 SOLAR ENERGY↗

NASA NTRS1978

Evaluation of materials for high performance solar arrays

A program has been underway to evaluate materials for advanced solar arrays which are required to provide power to weight ratios up to 100 W/kg. Severe mission environments together with the lack of knowledge of space environmental materials degradation rates require the generation of irradiation and outgassing engineering data for use in the initial design phase of the flight solar arrays. Therefore, approximately 25 candidate array materials were subjected to selected mission environments of vacuum, UV, and particle irradiation, and their mechanical and/or optical properties were determined where appropriate.

Whitaker, A. F.↗

NASA NTRS1991

Solid C triple bond N bearing material on outer solar system bodies

Recent telescopic observations have led to the identification of cyanogroup-containing molecules in the dark surface solids of several D-class asteroids, cometary dusts, and the rings of Uranus, as well as the low-albedo atmosphere of Iapetus. The occurrence of the 2.2-micron overtone of C triple-bond N's stretching fundamental mode in all four classes of small solar system bodies is presently suggested to serve as a diagnostic of both exposure duration and degree of modification of surface materials.

Cruikshank, Dale P.↗

NASA NTRS1981

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

Encapsulant materials and processes for the production of cost effective, long life solar cell modules are identified, and evaluated. Ethylene vinyl acetate lamination pottant studies are conducted with respect to the time/temperature cure requirements for successful use of this compound. The time needed to produce successful gel contents are redetermined at a variety of temperatures and are related to the peroxide half life temperature curve. Formulation of the butyl acrylate syrup casting pottant is complete. The formulation contains an ultraviolet stabilizer system and is cured with an initiator that presents no shipping or handling hazards. The catalyzed syrup is stable at room temperature and has a pot life of at least an eight hour period of time. The syrup cures to a transparent rubber in 18 minutes at a temperature of 60 C.

Willis, P. B.↗

NASA NTRS1984

Material Selection Considerations for Solar Ponds

Among the various candidate materials tested, stainless steel shows the best potential for applications as heat exchanger components in solar ponds. Even stainless steel may lead to pitting type of corrosion. Weight loss measurements are probably unsatisfactory for corrosion evaluation in solar pond situations. Also included are the results from the potentiodynamic anodic polarization analysis, corrosion rate calculation via corrosion behavior diagrams, and immersion weight loss measurements.

Sastri, S.↗

NASA NTRS1985

Electrical research on solar cells and photovoltaic materials

A systematic study of the properties of various polymer pottant materials and of the electrochemical corrosion mechanisms in solar cell materials is required for advancing the technology of terrestrial photovoltaic modules. The items of specific concern in this sponsored research activity involve: (1) kinetics of plasticizer loss in PVB, (2) kinetics of water absorption and desorption in PVB, (3) kinetics of water absorption and desorption in EVA, (4) the electrical properties at PVB as a function of temperature and humidity, (5) the electrical properties of EVA as a function of temperature and humidity, (6) solar cell corrosion characteristics, (7) water absorption effects in PVB and EVA, and (8) ion implantation and radiation effects in PVB and EVA.

Orehotsky, J.↗

NASA NTRS1981

Investigation of test methods, material properties, and processes for solar cell encapsulants

Encapsulant materials and processes for the production of cost-effective, long-life solar cell modules were investigated. The following areas were explored: (1) soil resistant surface treatment; (2) corrosion protecting coatings from mild steel substrates; (3) primers for bonding module interfaces; and (4) RS/4 accelerated aging of candidate encapsulation compounds

Willis, P. B.↗

NASA NTRS1993

LEO effects on candidate solar cell cover materials

In 1984, the LDEF (Long Duration Exposure Facility) was placed in LEO (Low Earth Orbit) for a mission planned to last approximately one year. Due to a number of factors, retrieval was delayed until 1990. An experiment, prepared under the direction of JPL, consisted of a test plate with thirty (30) individual thin silicon solar cell/cover samples. The covers consisted of conventional cerium doped microsheet platelets and potential candidate materials, such as FEP Teflon, silicon RTV's, glass resins, polyimides, and a silicone-polyimide copolymer encapsulant. The effects of the LDEF mission environment (micrometeorite/debris impacts, atomic oxygen, UV, and particulate radiation) on the samples are discussed.

Stella, Paul M.↗

NASA NTRS1981

Improved performance from solar cells made from candidate sheet silicon materials

Performance of solar cells made from various candidate silicon sheets is updated and the results are presented. Solar cells were fabricated using a baseline process and other process variations, and tested under AM1 conditions. Performance of the baseline solar cells indicates that remarkable improvements in material quality have been achieved for most of the sheets, showing efficiencies close to that of the control cells made from conventional CZ silicon. Process variations (or additions), in general, have resulted in significant improvements in all performance with a degree of change dependent on the process chosen and to a certain extent the sheet quality.

Yoo, H. I.↗

NASA NTRS1987

Selection of high temperature thermal energy storage materials for advanced solar dynamic space power systems

Under the direction of NASA's Office of Aeronautics and Technology (OAST), the NASA Lewis Research Center has initiated an in-house thermal energy storage program to identify combinations of phase change thermal energy storage media for use with a Brayton and Stirling Advanced Solar Dynamic (ASD) space power system operating between 1070 and 1400 K. A study has been initiated to determine suitable combinations of thermal energy storage (TES) phase change materials (PCM) that result in the smallest and lightest weight ASD power system possible. To date the heats of fusion of several fluoride salt mixtures with melting points greater than 1025 K have been verified experimentally. The study has indicated that these salt systems produce large ASD systems because of their inherent low thermal conductivity and low density. It is desirable to have PCMs with high densities and high thermal conductivities. Therefore, alternate phase change materials based on metallic alloy systems are also being considered as possible TES candidates for future ASD space power systems.

Lacy, Dovie E.↗

NASA NTRS1987

Selection of high temperature thermal energy storage materials for advanced solar dynamic space power systems

Lacy, Dovie E.↗

NASA NTRS1980

Material problems in solar sail development

The paper considers the solar sail principle as an effective means of space propulsion. The heliogyro configuration is discussed including the hub structures, the flap-hinge brace assembly, and the blade. The material requirements of the sail film made of metallized polymers, the tendons produced from a polymer-graphite fiber composite, and battens constructed of graphite/epoxy tubings are considered, noting that not all of these materials were readily available. It was concluded that the primary material problems are the environmental degradation of polymer films, the meteoroid hazard, and the production capacity for large polymer film quantities.

Steurer, W. H.↗

NASA NTRS1994

Origins of interstellar and solar system: Carbonaceous materials

Carbon is a crucial atom in cosmochemistry. It is well-established that carbon is synthesized in stellar interiors after the main sequence, is ejected by red giants as small carbonaceous grains during their 'carbon star' phase, resides in the interstellar medium, and was later incorporated into the solar system. The mechanisms of carbon grain formation and later chemical processing are complex because, with only small thermodynamic differences, carbon can take on a bewildering variety of forms: diamond; oxides; carbides; graphite; aliphatic hydrocarbons; polycyclic aromatic hydrocarbons (PAH's); fullerenes; amorphous carbon; and other compounds. These are evidence for many of the forms of carbon found in astronomical observations. We seek to understand the possible astrophysical sites and conditions of the origins of different forms of carbon by combining state-of-the-art capabilities of carbon chemistry with astrophysical modeling. The work is a collaboration between Prof. Frenklach, a leading carbon materials scientist with both laboratory and computer modeling expertise and Prof. Feigelson, an astrophysicist with interests in star formation. The largest effort under this grant was devoted to developing this concept into a comprehensive quantitative model. In addition to explaining the astronomical properties of red giants producing carbonaceous grains, our model also can incorporate recent meteoritic findings. Finally, our induced nucleation grain formation model provides a natural explanation for the widespread presence of PAH emission bands in the Galactic interstellar medium. A brief synopsis of other activities sponsored under this grant and a list of publications from this grant is included.

Feigelson, Eric D.↗

NASA NTRS1978

Encapsulation task of the low-cost silicon solar array project. Investigation of test methods, material properties, and processes for solar cell encapsulants

The results of an investigation of solar module encapsulation systems applicable to the Low-Cost Solar Array Project 1986 cost and performance goals are presented. Six basic construction elements were identified and their specific uses in module construction defined. A uniform coating basis was established for each element. The survey results were also useful in revealing price ranges for classes of materials and estimating the cost allocation for each element within the encapsulating cost goal. The six construction elements were considered to be substrates, superstrates, pottants, adhesives, outer covers and back covers.

Willis, P. B.↗