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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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At least 235 records · Page 13
All sourcesNASA NTRSDOE OSTI
DOE OSTI2016

Chapter 9: Reliability

This chapter describes the accumulated knowledge on CPV reliability with its fundamentals and qualification. It explains the reliability of solar cells, modules (including optics) and plants. The chapter discusses the statistical distributions, namely exponential, normal and Weibull. The reliability of solar cells includes: namely the issues in accelerated aging tests in CPV solar cells, types of failure and failures in real time operation. The chapter explores the accelerated life tests, namely qualitative life tests (mainly HALT) and quantitative accelerated life tests (QALT). It examines other well proven and experienced PV cells and/or semiconductor devices, which share similar semiconductor materials, manufacturing techniques or operating conditions, namely, III-V space solar cells and light emitting diodes (LEDs). It addresses each of the identified reliability issues and presents the current state of the art knowledge for their testing and evaluation. Finally, the chapter summarizes the CPV qualification and reliability standards.

14 SOLAR ENERGY↗
DOE OSTI2025

Historical and Future Learning for the New Era of Multi-Terawatt Photovoltaics

Solar photovoltaics (PV) is entering a new era of multi-terawatt deployment, with 2 TW already in service and more than 75 TW predicted in many scenarios by 2050. This next era has been enabled by over five decades of cumulative advances in PV module cost reduction, performance and reliability. The current scale of deployment also introduces new needs, opportunities and challenges. In this Perspective we frame a path forwards based on learning, broadly defined as a combination of expansion of knowledge and advances through research and development, experience and collaboration. We discuss historical topics where learning has driven PV deployment until now, and emerging areas that are required to sustain high levels of future deployment. We expect progress to continue in terms of module price, performance and reliability, driven by advances in PV cell and module design, the emergence of tandem devices and increased focus on extending module lifetimes. Large-scale deployment also means large-scale sustainability and responsibility. We therefore posit that additional metrics, such as the impact on global CO2 emissions, resource consumption and design for reuse and recycling, will become increasingly important to the PV industry and provide opportunities for further learning.

14 SOLAR ENERGY↗
DOE OSTI2021

Evaluation of Low-Pressure-Sintered Multi-Layer Substrates for Medium-Voltage SiC Power Modules: Preprint

Direct-bonded aluminum (DBA) multi-layer substrates have been fabricated using low-pressure silver sintering. These multi-layer substrates can be used to reduce the peak electric field strength inside power modules. This benefit is particularly important for medium-voltage silicon carbide (SiC) MOSFETs due to their higher operating voltages. The voiding content and defect density of the bond used to create the multi-layer substrate stackup is critical to the thermal performance and reliability of the power module. This work two low-pressure-assisted sintering techniques; one using nano-silver preform and the other using nano-silver paste to bond 23 mm by 49 mm DBA substrates. Scanning acoustic microscopy (C-SAM) is used to evaluate the bond quality after sintering. To evaluate the reliability of the sintered multi-layer substrates, passive thermal cycling from –40 °C to 200 °C was performed. Cross-sections were cut at pre-determined intervals and imaged with Scanning Electron Microscopy (SEM). After 1,000 thermal cycles, minor cracking was observed, but no failures have occurred.

28 EE - Advanced Manufacturing Office (EE-5A)↗
NASA NTRS1972

Conceptual design and feasibility evaluation model of a 10 to the 8th power bit oligatomic mass memory. Volume 1: Conceptual design

The oligatomic (mirror) thin film memory technology is a suitable candidate for general purpose spaceborne applications in the post-1975 time frame. Capacities of around 10 to the 8th power bits can be reliably implemented with systems designed around a 335 million bit module. The recommended mode was determined following an investigation of implementation sizes ranging from an 8,000,000 to 100,000,000 bits per module. Cost, power, weight, volume, reliability, maintainability and speed were investigated. The memory includes random access, NDRO, SEC-DED, nonvolatility, and dual interface characteristics. The applications most suitable for the technology are those involving a large capacity with high speed (no latency), nonvolatility, and random accessing.

Recksiedler, A. L.↗
DOE OSTI2021

PV Evolution in the Light of Circular Economy

As photovoltaic (PV) deployments increase, the increasing material volume presents challenges throughout the supply chain and eventual end-of-life waste management. Quantifying the value of lifetime, reliability, repair, reuse, recycling, and other options to increase circularity can help identify and prioritize research and technical solutions required to integrate PV into the circular economy. In this work, we capture the evolution of PV module technology, such as improved reliability and increasing market share of glass/glass modules. We discuss material circularity, lifetime and reliability, and energy return on investment as quantitative metrics to define and evaluate circularity and sustainability.

bifacial↗
DOE OSTI2020

Activation Energy for Solder Bond Degradation: Thermal Cycling of Field-aged Modules at Multiple Upper Temperatures

The reliability of solder joints in the solar cell metallization-interconnect system influences the lifetime of photovoltaic modules. Two field-aged modules-one with Sn 62 Pb 36 Ag 2 solder at the solder joints (Solarex MSX 60), and the other with the standard Sn 60 Pb 40 solder (Siemens M55)-were subjected to a modified thermal cycling (TC) test of IEC 61215. Three sections in each module were maintained at 85 degrees C, 95 degrees C, and 105 degrees C during the 15-minute high temperature dwell time. Current equivalent to the module short-circuit current was injected through the module when the chamber temperature was above 25 degrees C to simulate regular field operation. This novel approach aims to induce thermomechanical fatigue (TMF) at the solder joints and intermetallic compound (IMC) formation at the metal/solder interfaces. The activation energy (E a ) for solder bond degradation was calculated based on the series resistance (R s ) increase in TC testing rather than power drop to avoid the effect of confounding variables. Module-level R s increase in MSX 60 module after TC800 cycles and in M55 module after TC400 cycles was 1.22% and 183.7%, respectively. The E a determined for the module with 2wt% Ag is 0.24 eV and for that with the standard solder is 0.27 eV. The solder bond degradation seems to have been driven by TMF rather than IMC formation for both modules.

14 SOLAR ENERGY↗
DOE OSTI2020

Predictive Models and Novel Accelerated Tests for the Reliability of Cell Metallization and Solder Joints in Photovoltaic Modules

Interconnect, solder, and metallization-related failures are the primary reason for premature Si-based photovoltaic panel failure [1, 2] and can lead to a cascade of other failures, including thermal events. This combination of high severity and high occurrence means that understanding interconnect-related failures is key to the long-term health of the photovoltaic industry, and it is crucial that the industry adopt efficient and effective tests that aid in design-for-reliability and manufacturing quality control.

14 SOLAR ENERGY↗
NASA NTRS1978

Center punched solar cell module development effort

The results are given of an advanced module development program with the objective of providing a low cost solar cell mechanical interconnect design. The design approach, which avoids soldering or welding operations, lends itself to automated assembly techniques thus supporting the Low-Cost Silicon Solar Array Project goals. The first group of six modules contained aluminum contact cells and the second group of six modules contained silver-titanium-palladium contact cells. Extensive component and environmental testing at the module level showed that reliable cell mechanical interconnection can be achieved when utilizing the proper electrical contact materials and pressures. A discussion is given of the module design, manufacturing procedure, test program, significant problem areas and solutions, and conclusions and recommendations as formulated and conducted by XEOS.

Ross, R. E.↗
NASA NTRS2010

Mission Reliability Estimation for Repairable Robot Teams

A mission reliability estimation method has been designed to translate mission requirements into choices of robot modules in order to configure a multi-robot team to have high reliability at minimal cost. In order to build cost-effective robot teams for long-term missions, one must be able to compare alternative design paradigms in a principled way by comparing the reliability of different robot models and robot team configurations. Core modules have been created including: a probabilistic module with reliability-cost characteristics, a method for combining the characteristics of multiple modules to determine an overall reliability-cost characteristic, and a method for the generation of legitimate module combinations based on mission specifications and the selection of the best of the resulting combinations from a cost-reliability standpoint. The developed methodology can be used to predict the probability of a mission being completed, given information about the components used to build the robots, as well as information about the mission tasks. In the research for this innovation, sample robot missions were examined and compared to the performance of robot teams with different numbers of robots and different numbers of spare components. Data that a mission designer would need was factored in, such as whether it would be better to have a spare robot versus an equivalent number of spare parts, or if mission cost can be reduced while maintaining reliability using spares. This analytical model was applied to an example robot mission, examining the cost-reliability tradeoffs among different team configurations. Particularly scrutinized were teams using either redundancy (spare robots) or repairability (spare components). Using conservative estimates of the cost-reliability relationship, results show that it is possible to significantly reduce the cost of a robotic mission by using cheaper, lower-reliability components and providing spares. This suggests that the current design paradigm of building a minimal number of highly robust robots may not be the best way to design robots for extended missions.

Trebi-Ollennu, Ashitey↗
DOE OSTI2016

Integrating a reservoir regulation scheme into a spatially distributed hydrological model

During the past several decades, numerous reservoirs have been built across the world for a variety of purposes such as flood control, irrigation, municipal/industrial water supplies, and hydropower generation. Consequently, natural streamflow timing and magnitude have been altered significantly by reservoir operations. In addition, the hydrological cycle can be modified by land use/land cover and climate changes. To understand the fine scale feedback between hydrological processes and water management decisions, a distributed hydrological model embedded with a reservoir component is of desire. In this study, a multi-purpose reservoir module with predefined complex operational rules was integrated into the Distributed Hydrology Soil Vegetation Model (DHSVM). Conditional operating rules, which are designed to reduce flood risk and enhance water supply reliability, were adopted in this module. The performance of the integrated model was tested over the upper Brazos River Basin in Texas, where two U.S. Army Corps of Engineers reservoirs, Lake Whitney and Aquilla Lake, are located. The integrated DHSVM model was calibrated and validated using observed reservoir inflow, outflow, and storage data. The error statistics were summarized for both reservoirs on a daily, weekly, and monthly basis. Using the weekly reservoir storage for Lake Whitney as an example, the coefficients of determination (R2) and the Nash-Sutcliff Efficiency (NSE) are 0.85 and 0.75, respectively. These results suggest that this reservoir module has promise for use in sub-monthly hydrological simulations. Enabled with the new reservoir component, the DHSVM model provides a platform to support adaptive water resources management under the impacts of evolving anthropogenic activities and substantial environmental changes.

Zhao, Gang↗
DOE OSTI2020

Investigation of Failure Modes, Mechanisms and Driving Forces for Electrically Conductive Adhesives as Interconnects in PV Modules

In this work we describe our current progress into investigating the reliability of ECA interconnects for PV modules. Preliminary thermal cycling experiments demonstrated that both cohesive and adhesive failure of the ECA joint are relevant failure modes that result in an increase of the joints electrical resistance. A thorough viscoelastic characterization of the candidate ECA was conducted to enable accurate numerical modeling of the joint’s response to thermal cycling. Combined with critical and subcritical fracture measurements, the numerical model elucidates that an additional fatigue mechanism exists which can result in fracture well below subcritical debonding threshold values. It is also demonstrated that fracture of the ECA is more sensitive to humidity than temperature and subcritical debonding mechanisms do exist which are again more sensitive to humidity.

41 EE - Solar Energy Technologies Office (EE-4S)↗
DOE OSTI2014

Modeling the irradiance and temperature dependence of photovoltaic modules in PVsyst

In order to reliably simulate the energy yield of photovoltaic (PV) systems, it is necessary to have an accurate model of how the PV modules perform with respect to irradiance and cell temperature. Building on previous work that addresses the irradiance dependence, two approaches to fit the temperature dependence of module power in PVsyst have been developed and are applied here to recent multi-irradiance and -temperature data for a standard Yingli Solar PV module type. The results demonstrate that it is possible to match the measured irradiance and temperature dependence of PV modules in PVsyst. As a result, improvements in energy yield prediction using the optimized models relative to the PVsyst standard model are considered significant for decisions about project financing.

14 SOLAR ENERGY↗
DOE OSTI2022

Instrumented Photovoltaic Modules for Environmental Characterization and Simulation Model Validation

Photovoltaic modules are subjected to various mechanical stressors in their deployment environments, ranging from installation handling to wind and snow loads. Damage incurred during these mechanical events has the potential to initiate subsequent degradation mechanisms, reducing useful module lifespan. Thus, characterizing the mechanical state of photovoltaic modules is pertinent to the development of reliable packaging designs. In this work, photovoltaic modules with strain gauges directly incorporated into the module laminate were fabricated and subjected to mechanical loading to characterize internal strains within the module when under load. These experimental measurements were then compared against results obtained by high-fidelity finite-element simulations. The simulation results showed reasonable agreement in the strain values over time; however, there were large discrepancies in the magnitudes of these strains. Both the instrumentation technique and the finite-element simulations have areas where they can improve. These areas of improvement have been documented. Despite the observed discrepancies between the experimental and simulated results, the module instrumentation proved to be a useful gauge in monitoring and characterizing the mechanical state. With some process improvements, this method could potentially be applied to other environments that a photovoltaic module will encounter in its lifetime that are known to cause damage and degrade performance.

14 SOLAR ENERGY↗
NASA NTRS1984

Solar-cell interconnect design for terrestrial photovoltaic modules

Useful solar cell interconnect reliability design and life prediction algorithms are presented, together with experimental data indicating that the classical strain cycle (fatigue) curve for the interconnect material does not account for the statistical scatter that is required in reliability predictions. This shortcoming is presently addressed by fitting a functional form to experimental cumulative interconnect failure rate data, which thereby yields statistical fatigue curves enabling not only the prediction of cumulative interconnect failures during the design life of an array field, but also the quantitative interpretation of data from accelerated thermal cycling tests. Optimal interconnect cost reliability design algorithms are also derived which may allow the minimization of energy cost over the design life of the array field.

Mon, G. R.↗
NASA NTRS1982

Reliability and performance experience with flat-plate photovoltaic modules

Statistical models developed to define the most likely sources of photovoltaic (PV) array failures and the optimum method of allowing for the defects in order to achieve a 20 yr lifetime with acceptable performance degradation are summarized. Significant parameters were the cost of energy, annual power output, initial cost, replacement cost, rate of module replacement, the discount rate, and the plant lifetime. Acceptable degradation allocations were calculated to be 0.0001 cell failures/yr, 0.005 module failures/yr, 0.05 power loss/yr, a 0.01 rate of power loss/yr, and a 25 yr module wear-out length. Circuit redundancy techniques were determined to offset cell failures using fault tolerant designs such as series/parallel and bypass diode arrangements. Screening processes have been devised to eliminate cells that will crack in operation, and multiple electrical contacts at each cell compensate for the cells which escape the screening test and then crack when installed. The 20 yr array lifetime is expected to be achieved in the near-term.

Ross, R. G., Jr.↗
NASA NTRS1984

Advanced module development overview

Crystalline silicon solar power modules are examined for reliability and cost effectiveness. A goal of 12% solar energy conversion efficiency is considered feasible at a cost of 12/kWh, and a decision is made to limit consideration to float zone silicon wafer and dendritic web silicone modules. A preliminary module packaging configuration of glass/ethylene vinyl acetate/plastic film is selected. Anticipated module efficiency levels are 12.6% at 25 C and 11.5% at NOCT (Nominal Operating Cell Temperature).

Smokler, M. I.↗