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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 OSTI2020

Fundamentals of Using Cracked Film Lithography to Pattern Transparent Conductive Metal Grids for Photovoltaics

The fundamentals of using cracked film lithography (CFL) to fabricate metal grids for transparent contacts in solar cells were studied. The underlying physics of drying-induced cracks were well-predicted by an empirical correlation relating crack spacing to capillary pressure. CFL is primarily controlled by varying the crack template thickness, which establishes a three-way tradeoff between the areal density of cracks, crack width, and spacing between cracks, which in turn determine final grid transmittance, grid sheet resistance, and the semiconductor resistance for a given solar cell. Since CFL uses a lift-off process, an additional constraint is that the metal thickness must be less than 1/3 of the crack template thickness. Furthermore, the transmittance/grid sheet resistance/wire spacing tradeoffs measured in this work were used to calculate solar cell performance: CFL-patterned grids should outperform screen-printed grids for narrow cells (0.5–2 cm wide) and/or cells with high semiconductor sheet resistance (=100 O/sq), making CFL attractive for monolithically integrated thin-film photovoltaic modules.

14 SOLAR ENERGY↗
DOE OSTI2026

Eutectic Processing of Semiconductor Colloidal Nanocrystals for Energy Applications

Colloidal semiconductor nanocrystals (NCs) offer a costeffective platform for light-energy conversion in X-ray scintillators, photovoltaics, lasers, and display technologies. Yet, device-relevant NCs often require complex heterostructured compositions, where lattice imperfections compromise the efficiency and stability of photoconversion processes. Here, we show that a simple synthetic detour through a eutectic state of II−VI semiconductor NCs (e.g., CdSe, ZnSe) with halide salts (e.g., CdCl 2 , ZnCl 2 ) overcomes this limitation by melting and reconstructing NC lattices into defect-free alloyed and core/shell architectures. Applied to ternary CdSeTe NCs, this process produces downconverters with record brightness and minimal line widths, delivering a 3-fold increase in film-side external quantum efficiency of commercial CdTe photovoltaic modules (First Solar Inc.). Meanwhile, eutectic processing of CdSe-based core/shell emitters yields an 8-fold enhancement in their photoluminescence stability under backlight operation, addressing the reliability bottleneck for display technologies. Together, these findings establish eutectic NC processing as a scalable route to efficient, durable photoconversion materials for energy applications.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2025

Electrolytic gold plating, stripping, and ion transport dynamics through a solid-state iodide perovskite

The pronounced electrochemical reactivity between halide perovskites and metal electrodes can introduce mobile extrinsic metal ions which can cause device instability or enable novel functionalities. Here we systematically investigate the kinetics of gold cation (Au + ) migration in indium tin oxide (ITO)/methylammonium lead triiodide (MAPbI 3 )/Au model devices under long-term potentiostatic biasing. Scanning electron microscopy (SEM), X-ray photoelectron spectroscopy (XPS), and density functional theory (DFT) analyses reveal that Au + ions, electrochemically generated at the Au anode, traverse the perovskite layer with diffusion coefficients on the order of 10 −11 to 10 −10 cm 2 s −1 and are subsequently reduced at the cathode as Au 0 clusters, resembling metal plating behavior in electrolytic cells and solid-state batteries during charging. Furthermore, reversing the applied bias strips the plated Au 0 , revealing reversibility suitable for bipolar resistive switching devices and providing direct evidence of the electrochemical and ionic nature of Au transport within the perovskite matrix. Quantitatively determining diffusion coefficients and ion concentrations provides foundational inputs for future drift-diffusion modelling opportunities and allows us to relate our findings to implications on long term operation of devices like photovoltaic modules. These results clearly demonstrate the solid-state electrochemical nature of perovskite devices, highlight methods to be more quantitative about ion transport properties, provide and emphasize the importance of disentangling electro-, photo-, photoelectrochemical processes for understanding device performance and unlocking new functionalities.

14 SOLAR ENERGY↗
DOE OSTI2026

Performance Modeling of Tandem Photovoltaics: A Yearlong Outdoor Degradation Analysis of a Ga⁢As//Si Minimodule

We present a performance modeling and degradation analysis framework for tandem photovoltaic modules, building upon established procedures for crystalline silicon devices and adapting them to account for the spectral sensitivity of multijunction technologies. The methodology employs filter criteria to select outdoor measurements close to standard test conditions (STC) under stable spectral and ambient conditions, followed by normalization of power production data with corrections for temperature, irradiance, and precipitable water vapor. We demonstrate this framework using a mechanically stacked four-terminal gallium arsenide (Ga⁢As) // silicon (Si) tandem solar minimodule deployed outdoors from October 2019 to January 2021 in Golden, Colorado, USA. We determined degradation rates of −4.1 ±0.2%/year for the Ga⁢As subcell and −2.5 ±0.9%/year for the Si subcell, with analysis of individual performance metrics indicating that packaging degradation, particularly delamination, was the dominant failure mode. Simulations using PVcircuit, an open-source equivalent-circuit solver, confirmed these findings. The presented methodology provides a reproducible foundation for performance modeling and degradation analysis of emerging tandem technologies.

14 SOLAR ENERGY↗
DOE OSTI2021

Spatio-Temporal Modeling of Field Surveyed Backsheet Degradation

Assessing photovoltaic module backsheet durability is critical to increasing module lifetime. Lab based accelerating testing has recently failed to predict large scale failures of widely adopted polymeric materials. Field surveyed data is critical to assess the performance of component lifetime. Using a documented field survey protocol, 13 field surveys where conducted. Each measurement is encoded with it's spatial location in respect to the other modules. By combining field survey data on degradation predictors with real time satellite weather data, data-driven predictive models of backsheet degradation were trained. LOESS models were constructed to investigate the spatial dependence of measurements. It was found that micro-climatic effects like tree-lines, ground surface changes, and elevation changes effected the magnitude and variance of the measurements. A GAM model was created to predict the value of degradation based on measured predictors. The model includes variables on the climate of the system and the location of each measurement in the PV mounting structure. The model performed well with an adj.R 2 of 0.95 for yellowness index prediction. The model was cross-validated using k-folds.

backsheet↗
DOE OSTI2021

Towards Validation of Advanced Accelerated Stress Testing Protocols through Failure Analysis and Materials Characterization

As the lifetime of photovoltaic modules increases toward the goal of 50 years, accelerated stress testing is critical to assessing the viability of newer, improved, and often cheaper materials in the field. However, the validation of accelerated testing to reproduce field failure has remained elusive. The recent developments of more advanced stress testing protocols utilizing sequential and combined stressors have provided another opportunity for validation. Using a suite of mechanical, chemical, and structural characterization methods we report the development of our approach using a known bad backsheet “AAA.” We then apply this approach to PVDF-based backsheets to further confirm the generalizability of this approach. The outcome of this work is two-fold: (1) validation of advanced accelerated testing protocols which will enable the prediction of field failures in new materials, and (2) deeper insights into the degradation mechanisms observed through the extensive characterization allowing for improved materials engineering and development.

accelerated aging↗
DOE OSTI2022

Spatiotemporal Modeling of Real World Backsheets Field Survey Data: Hierarchical (Multilevel) Generalized Additive Models

Assessing photovoltaic module backsheet durability is critical to increasing module lifetime. Laboratory-based accelerating testing has recently failed to predict large scale failures of widely adopted polymeric materials. Additionally, there is a growing concern on characterizing the non-uniformity of field exposure. Therefore, data from field surveys are critical to assess the performance of component lifetimes. Using a documented field survey protocol, 19 field surveys were conducted. The focus of this survey strategy is to investigate spatial continuity in degradation modes. By combining field survey data with real-time satellite weather data, stressor / response models have been trained. Generalized additive Models (GAM) model was created to predict the value of degradation based on measured predictors. Two different GAM constructions were testing using different implementations of basis splines. The model includes variables on the environmental stressors of the system and the location of each measurement in the PV mounting structure. The incorporation of hierarchical structure into the models allowed for material specific degradation rates, while maintaining the assumption of a global trend. The model performed well with an adjusted R2 of 0.975 for yellowness index prediction.

backsheet↗
DOE OSTI2024

A Generic and Multifunctional Electromagnetic Transient Model for Grid-Following Inverters

This paper presents a generic and multifunctional electromagnetic transient (EMT) dynamic model of grid-following (GFL) inverter-based resources (IBRs) using the PSCAD software platform. The features of the model include flexibility in selecting various types and combinations of DC sources covering photovoltaic modules, battery modules, and ideal DC-source modules as well as flexibility in selecting either switching or averaged models of the inverter. This model also covers exhaustive lists of controller algorithm, including open-loop/closed-loop PQ dispatch control, DC voltage and AC terminal voltage control, and conventional current control designed in the dq-domain, the ..alpha....beta.. -domain, and the positive-/negative-sequence domain. Moreover, this model is equipped with flexibility in selecting various types of current-limiting schemes, including saturation-based and latching-based current limiters, and anti-windup protection. Also, the EMT model is agnostic to the MVA rating and is suitable for interfacing transmission systems by complying with IEEE Std. 2800. The generality in the power circuits and the multifunctional options in the operation and control of the developed EMT model make it suitable for both academia and industry to study various power system aspects, including, but not limited to, the fault behavior of GFL IBRs, the impacts on the protection system, and the transient stability of a system interfaced with large numbers of GFL IBRs.

integrated circuit modeling↗
DOE OSTI2024

PV Degradation Tools [SWR-20-71]

This open-source tool functions for calculating degradation of photovoltaic modules. For example, functions to calculate front and rear relative Humidity, as well as Acceleration Factors. A degradation calculation function is also being developed, considering humidity and spectral irradiances models.

Holsapple, Derek↗
DOE OSTI2025

PVmesh [SWR-24-123]

PVmesh is an open-source Python tool for generating high-fidelity, adaptive finite-element meshes for photovoltaic modules. It supports multilayer panel geometries, frame details, and mounting zones that are often difficult to mesh robustly with generic workflows. Built on Gmsh, PVmesh automates geometry construction, partitioning, domain/boundary tagging, and export for downstream finite-element solvers.

He, Xin [National Laboratory of the Rockies (NLR),↗
DOE OSTI2025

Developing the Science Basis for Understanding Polymer Encapsulant Degradation Mechanisms: DuraMAT 2.0 Final Project Report

Polymeric encapsulants are essential materials in photovoltaic modules, protecting sensitive electronics from the environment while providing mechanical integrity to the multilayered assembly. However, these polymeric materials are susceptible to degradation processes driven by the ingress of environmental species, ultraviolet radiation, thermal stresses, and mechanical loading. In this study, we employ a combined atomistic simulation and accelerated aging experimental approach to study the molecular-scale mechanisms of encapsulant degradation. Classical molecular dynamics simulations quantify the diffusion of environmental and degradation species through the polymer matrix, producing composition-specific diffusion coefficients. Reactive simulations characterize activation energy barriers and reaction rate constants for key chemical pathways. In parallel, thermal-desorption analyses coupled with mass spectrometry monitor the emergence and concentration profiles of degradation products under controlled stressor conditions. By integrating simulation and experiment, we establish quantitative correlations between polymer composition, species diffusivity, and chemical reactivity. We anticipate that these relations and quantitative values could serve as high-fidelity inputs to reaction-diffusion models, enabling physics-informed lifetime predictions and guiding the design of more durable encapsulant materials for solar energy applications.

36 MATERIALS SCIENCE↗
DOE OSTI2026

NREL Validation of S3.2 and S3.3 (CRADA Final Report)

The scope of work for S3.2 and S3.3 validation includes cooperative planning, execution, and analysis of all recommended and agreed-upon test protocols to determine the suitability of the product for long-term deployment of the photovoltaic modules to a broad range of climates. The test plan will be established within two months of project initiation, and NREL will write monthly reports for the duration of the work.

14 SOLAR ENERGY↗
DOE OSTI2023

Simulated Impact of Shortened Strings in Commercial and Utility-Scale Photovoltaic Arrays

The deliberate removal of photovoltaic modules from a string can occur for various reasons encompassing maintenance, measurements, theft, or failure, reducing that string length relative to others when replacement modules are not available and there are not any viable alternative makes and models that could be inserted. This phenomenon, delineated in our prior experimentally validated research, manifests two significant effects: (1) a shift in the ideal maximum power point and (2) the induction of potentially substantial reverse currents in the shortened strings at open-circuit voltage, VOC. However, the scalability and asymptotic limits of these observed behaviors concerning array size remained undetermined. In this study, we elucidate the operational dynamics of such arrays by manipulating two mismatch-contributing variables in simulated arrays of up to 900 strings: the number of removed modules per string (indicative of the level of mismatch, ranging up to 5) and the quantity of shortened strings (1 to 60). Simulation outcomes underscore that mismatch severity impacts array operation more than the proportion of shortened strings. This research delves into the practical ramifications of operating with shortened strings, including implications for low-irradiance operation and the manifestation of deleterious reverse currents (>35 A in specific cases), emphasizing the need for careful array configuration for optimal performance and safety in these implementations.

Energy & Fuels↗
DOE OSTI2020

Methods and systems for determining soiling on photovoltaic devices

An aspect of the present disclosure relates to radiating light on to a front surface of a glass pane comprising a first surface and a second surface defining a thickness between the first surface and the second surface, wherein the first surface is substantially parallel to the second surface; detecting a transmittance of the light through the glass pane; comparing the transmittance through the glass pane to a reference transmittance value corresponding to a clean reference glass pane; and determining, using the transmittance and the reference transmittance, a soiling metric of a photovoltaic module.

14 SOLAR ENERGY↗
DOE OSTI2022

Spatiotemporal Modeling of Real World Backsheets Field Survey Data: Hierarchical (Multilevel) Generalized Additive Models: Preprint

Assessing photovoltaic module backsheet durability is critical to increasing module lifetime. Lab based accelerating testing has recently failed to predict large scale failures of widely adopted polymeric materials. Field surveyed data is critical to assess the performance of component lifetime. Using a documented field survey protocol, 13 field surveys where conducted. Each measurement is encoded with it's spatial location in respect to the other modules. By combining field survey data on degradation predictors with real time satellite weather data, data-driven predictive models of backsheet degradation were trained. LOESS models were constructed to investigate the spatial dependence of measurements. It was found that micro-climatic effects like treelines, ground surface changes, and elevation changes effected the magnitude and variance of the measurements. A GAM model was created to predict the value of degradation based on measured predictors. The model includes variables on the climate of the system and the location of each measurement in the PV mounting structure. The model performed well with an adj:R2 of 0:95 for yellowness index prediction. The model was cross-validated using k-folds.

backsheet↗
DOE OSTI2023

Tunable negative coefficient thermal expansion materials and composites

The present disclosure is directed to variable composition ceramics. Zr (2−x) Hf (x) WP 2 O 12 and Hf 2 WP 2 O 12 exhibit large negative thermal expansion that is linear over a large temperature range up to at least 900° C., These new ceramic material particles may be mixed with polymers to make a composite suitable for use in backsheets for photovoltaic modules or in other applications. The thermal expansion coefficient of the composite can be tailored to match that of the solar cell in order to reduce stress resulting from daily thermal cycling.

Gordon, Margaret Ellen↗
DOE OSTI2026

Robotics for Energy Infrastructure Construction on Earth and Beyond: Pilot Study Exploring Level 3-4 Semi-Autonomous Installation of a Reduced-Scale Photovoltaic Power Plant Prototype: Preprint

There is a growing need to build energy infrastructure at massive scale on both Earth and in space. On Earth, increasing electricity demand from applications such as AI data centers is driving rapid expansion of power systems, while in space, long-duration missions such as lunar operations require reliable and resilient energy infrastructure that can be deployed quickly. These needs outpace the capabilities of conventional construction methods. Robotic construction offers a path to faster, lower-cost, and more consistent deployment, yet most existing approaches focus on automating individual tasks rather than end-to-end assembly. The Industrialized Construction Innovation (ICI) team at the National Laboratory of the Rockies (NLR), in collaboration with the Colorado School of Mines, has been investigating robotics and automation strategies for rapid end-to-end energy infrastructure construction. This paper presents a pilot study demonstrating level 3-4 semi-autonomous, end-to-end robotic assembly of a reduced-scale photovoltaic power plant prototype under terrestrial conditions. The approach combines hardware redesign of photovoltaic components for robotic compatibility, discrete-event and physics-based robotic simulations in synthetic environments, and sim-to-real deployment to execute end-to-end robotic assembly of[NM1.1][NM1.2] tracking components, structural members, photovoltaic modules, and embedded electrical connections. The pilot identifies key limitations like tolerance management, perception and localization, end effector capability, fastening methods, and multi-physics simulation fidelity, that must be addressed to enable end-to-end robotic assembly of full-scale energy infrastructure. The study highlights how these insights inform scaling strategies for terrestrial energy infrastructure and adaptation to unstructured and extreme environments, including off-world scenarios such as robotic assembly of vertical tall lunar towers.

14 SOLAR ENERGY↗