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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 343 records · Page 19
All sourcesNASA NTRSDOE OSTI
DOE OSTI2022

Final Scientific/Technical Report-FREE-piston Zero Emissions Refrigerator (FREEZER)

The FREE-piston Zero Emissions Refrigerator (FREEZER™) is a natural refrigerant Stirling-cycle cooler developed by AMSC in partnership with Heatcraft, targeted as a replacement refrigeration system for walk-in coolers or freezers found commonly in restaurants, convenience stores, supermarkets, etc. The FREEZER™, combined with a closed-loop CO2 heat-transfer system, had the goal to provides an efficient (Target COP = 1.4), zero ODP (Ozone Depletion Potential) and near zero GWP (Global Warming Potential) refrigeration solution with no synthetic, flammable, or toxic refrigerants. Other near zero GWP refrigeration systems do not exist at the scale and performance level of FREEZER. ARPA-E Continuation Funding enabled the design and fabrication of one Advanced Development Unit (ADU) cooler and two Field Test Unit (FTU) coolers, and a new revised Field Test Unit (new FTU). Heatcraft was to extensively test the various coolers at their facilities, which closely simulate real-world conditions. The original plan was to install and operate FREEZER FTUs alongside a traditional cooling solution at one or more customer locations to obtain data on direct performance comparisons with existing commercial refrigeration systems. Success in this FREEZER refinement and field-test project will establish the basis for a new class of environmentally friendly refrigeration systems that will revolutionize the industry. The hardware developed under the program is shown below in Figure 1. Five Stirling-cycle machines were built within the program, with a sixth cooler still under construction. The original DU and the ADU coolers met the performance target with a coefficient of performance (COP) of 1.2. The FTU was underperforming during the initial tuning of the free-piston Stirling cycle dynamics when there was a catastrophic failure of the fasteners on pressure boundary. This caused a pause to the program while the failure mechanism was investigated. The root cause was an inadequate flange design that allowed an excessive cyclic loading on the fasteners, leading to a fatigue failure. It was determined that existing FTU design could not be reasonably salvaged in a safe manner, and that fact, combined with the lower-than-expected performance of the new experimental heat exchanger modules lead to the design of the “new FTU” with a more conventional shell-and-tube heat exchanger design which should get close to the design target COP of 1.4, but have a higher overall machine cost. The program ran out of time before the fabrication of the new FTU was completed, but AMSC is still working on the cooler, with the majority of the parts fabricated, and hopes to have the unit under test sometime in early 2022, after which it will be shipped to Heatcraft for additional testing.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2021

A novel defoamer for processing nuclear waste: Testing and performance

Abstract Legacy radioactive waste from nuclear weapons material processing is the biggest environmental challenge in the state of South Carolina, and one of the biggest in the United States. Although substantial progress has been made in processing and vitrifying high‐level radioactive waste at the Savannah River site, approximately 35 million gallons remains to be treated and dispositioned. In this article, we show the development of a new defoamer for use in the processing of high‐level radioactive waste. The application of the new defoamer is not only more effective at controlling foam but will shorten the batch processing time leading to safer and more efficient processing. This has the potential to help shorten the overall site mission lifetime, saving the federal government hundreds of millions of dollars. The novel aspect of the new defoamer is its effectiveness and stability in the harsh conditions needed for processing high‐level radioactive waste: high temperatures, pH 4–13, strong oxidizing and reducing agents, and numerous metal catalysts. The defoamer will replace an existing antifoam agent that decomposes to form multiple flammable gases. Because the existing antifoam agent decomposes quickly, processing changes increased processing time. Statement of novelty We demonstrate that a new defoamer has been developed for use in processing high‐level radioactive waste. This novel defoamer is effective and stable in the harsh processing conditions with no detectable flammable by‐products. Because the existing antifoam agent decomposes quickly, processing changes, including lowering acid addition rates and evaporation rates, increased processing time. The new defoamer is not only more effective at controlling foam but will shorten the batch processing time and lead to safer and more efficient processing by eliminating the production of flammable gases. Statement of industrial relevance Foaming is of great concern in many industrial processes involving three‐phase gas/liquid/fine‐solids systems, like in water evaporation, mineral floatation, air sparging in situ remediation techniques, and in those found in the paper industry.

Lambert, Dan P.↗
DOE OSTI2025

Anion exchange membrane test protocol validation

This study presents the validation of protocols for measuring ion exchange capacity (IEC) and alkaline stability of anion exchange membranes (AEMs) for low-temperature water electrolysis. While protocols are often tested within individual laboratories, their results across multiple laboratories with varying equipment, environmental conditions, and personnel qualification remain unverified. The validation involved Los Alamos National Laboratory (LANL), National Renewable Energy Laboratory (NREL), and University of Oregon (UO) using the same commercially available AEM to assess reproducibility and reliability of the protocols under diverse conditions. For the IEC protocol, results across laboratories were consistent within ±10% of the NMR-determined reference value. The alkaline stability protocol could pose greater challenges due to factors such as variations in sample collection timing, preservation methods, and analytical techniques, but consistent test results for percentage IEC loss were demonstrated across institutions. These results highlight the reliability and applicability of the protocols, emphasizing the importance of validation to ensure consistency in diverse research environments.

08 HYDROGEN↗
DOE OSTI2020

2020 LANL Contributions to the BATS Test in WIPP

The DOE Office of Nuclear Energy (DOE-NE) repository research and development program seeks to provide a sound technical basis for multiple viable disposal options, increase confidence in the robustness of generic disposal concepts, and develop science and engineering tools needed to support disposal concept implementation. Sandia, Los Alamos, and Lawrence Berkeley National labs are conducting research into salt, which includes the Brine Availability Test in Salt (BATS) field test at the Waste Isolation Pilot Plant (WIPP), a DOE Office of Environmental Management facility. BATS is leveraging the existing infrastructure associated with the WIPP to advance science informing generic disposal concepts. BATS is an ongoing heated borehole experiment being conducted in the WIPP underground. The goal of this experiment is to reduce the uncertainty associated with spent nuclear fuel disposition in geologic salt formations. The BATS experiments is designed to accomplish this by increasing our understanding of brine migration in salt, assessing damaged zones from mining and drilling, simulating a post-closure environment, confirming salt properties, and providing data for model validation. Phased testing for generic salt repository R&D was proposed in 2015. Subsequently, borehole thermal testing was developed as a first step in this process. This document summarizes the work conducted on the BATS experiment during fiscal year 2020 with an emphasis on the contributions by Los Alamos National Lab.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2022

Needs and Opportunities for Testing of Hydropower Technology Innovations

Despite hydropower’s status as a well-established technology, changes in the global energy sector have prompted a variety of necessary hydropower technological innovations. Examples include efficient lowhead turbines, more flexible and dispatchable hydropower and pumped storage systems to complement variable and intermittent renewable resources, and technologies providing higher environmental performance. However, while innovative technologies are currently being proposed to meet these development challenges, small hydropower facility owners do not have sufficient risk-bearing capacity to adopt new, unvalidated technologies. This discourages manufacturers from bringing nascent technologies to market and stalls the technological growth of the sector. To reduce the risks associated with new technologies and promote further innovation, systemic (and sometimes unconventional) validation activities and new testing capabilities for hydropower are highly desired. These testing capabilities must demonstrate the safety, environmental acceptability, reliability, and performance of innovative technologies to quantify their value compared with existing technologies. Establishing these capabilities through dedicated testing facilities will be key to promoting hydropower growth in the United States. Following direction from the House Energy and Water Development Committee, the US Department of Energy’s Water Power Technologies Office (WPTO) has been tasked with understanding the state of hydropower testing in the United States. This scoping report discusses the needs and opportunities of hydropower testing in the United States, with a specific focus on small hydropower. Future developments will likely mostly target low-head sites with less than 30 ft (9.1 m) from new stream-reach developments, non-powered dam retrofits, and rehabilitation/upgrade of existing plants.

13 HYDRO ENERGY↗
DOE OSTI2025

Findings on subtask 3.3 – applicability of automated brine chemistry determinations for treatment and recovery processes through facility automation/modularization: engineering design study

Under the Energy & Environmental Research Center’s (EERC’s) ~$\$$22 million Phase II Brine Extraction and Storage Test (BEST) Program, a multimillion-dollar brine treatment technology test bed facility was established in western North Dakota to provide a platform for evaluating developing technologies and approaches for brine treatment and volume reduction. The initial facility, and associated research effort, was funded by the U.S. Department of Energy (DOE), with in-kind contributions provided by several industry participants and the state of North Dakota. Since its opening, the Brine Technology Test Facility (BTTF) has supported performance evaluations of desalination technologies capable of treating high-salinity produced water (PW) and enabled data collection for multiple approaches of PW management and critical material recovery. As part of the decommissioning process for the original project, facility ownership and liability were transferred to Select Water, which is providing the EERC with a continuing site access option for state or federal research and/or commercial technology development. This report documents the findings from a design study conducted by the EERC and the engineering firm that was originally contracted to design and construct the facility (Advanced Engineering and Environmental Services, LLC [AE2S]) that evaluated the current status of BTTF and its systems and developed a retrofit design to increase the facility’s capabilities through automation and modularization of its PW treatment infrastructure. The proposed retrofit will provide DOE and industry with an expanded range of conditioned PW that can be produced at the facility for evaluating fit-for-purpose water treatment technologies, online instrumentation for brine chemistry determination, and systems that recover critical materials like lithium and magnesium. The current facility consists of an 9600-square-foot facility that includes a 40-foot by 65-foot Class 1, Division 2-rated demonstration area and associated control rooms and lab-ready space capable of sourcing oil and gas PW and wastewater from industrial sources or tailoring brine compositions up to 300,000 mg/L total dissolved solids (TDS) and supplying them at rates up to 25 gpm for extended-duration technology demonstrations. The colocation of the facility with Select Water’s water management facilities allows for access and unloading of more than 10,000 bbl/day of trucked water delivered to site and associated access to on-site Class I and Class II brine disposal wells and nearby hazardous waste landfills operated and/or contracted by Select Water to dispose of concentrate and/or effluents associated with the testing.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2020

Investigation of Non-Nuclear Plowshare and Vela Uniform Sites - 20447

The Plowshare Program was initiated by the Atomic Energy Commission, a predecessor agency to the US Department of Energy (DOE), to investigate peaceful uses of nuclear devices. 'Vela Uniform,' part of the broader Project Vela, was designed to use nuclear and other explosions to increase the capability of the United States to detect nuclear tests through seismicity. There were underground nuclear tests conducted off the Nevada National Security Site (NNSS) as part of the Plowshare Program (e.g., the Gnome-Coach, New Mexico, Site) and the Vela Uniform Program (e.g., Project Shoal, Nevada, Site) at which the DOE Office of Legacy Management (LM) has been conducting long-term surveillance and maintenance since fiscal year (FY) 2006. There are many additional locations, particularly for the Plowshare Program, that were considered for nuclear tests or used for non-nuclear tests off the NNSS. Some were only named on paper, but at 30 sites, field work such as drilling test wells and conducting tests using conventional explosives was done. A Plowshare nuclear explosion had been proposed at Project Chariot but was canceled in 1962. In 1992, the discovery of soils contaminated with radionuclides from tracer experiments led to a cleanup by the DOE Office of Environmental Management (EM) of the Project Chariot, Alaska, Site, which was completed in 1994. Following the cleanup of the Project Chariot site, EM was concerned that there might be environmental liabilities at other Plowshare or Vela Uniform sites where field investigations were done, even if the nuclear test was never conducted. The EM Program at the Nevada Site Office began examining records and visiting selected locations that were evaluated for Plowshare and Vela Uniform non-nuclear tests. In total, 161 Plowshare and 14 Vela Uniform sites or proposed projects were identified. The Desert Research Institute (DRI) created summaries of the work carried out at these sites and developed a collection of unclassified documents for them. Preliminary investigations had been conducted at these sites by both LM and EM since the early 2000's. In 2016, in preparation for accepting responsibility for the sites, LM started a program to determine if there were any environmental or safety liabilities associated with them. In 2019, LM formally accepted responsibility for these sites off the NNSS where non-nuclear explosive tests were conducted or where underground nuclear tests were proposed as part of the Plowshare and Vela Uniform programs but were never conducted. LM responsibilities will include maintaining institutional knowledge of the sites, responding to public inquiries, and addressing any concerns at each site. To minimize risk associated with site management, LM has archived all historical records compiled by DRI and has performed limited investigations at sites identified by the prior studies as having a higher potential liability. Preserving records related to site operations reduces the risk of doing unnecessary site investigations in the future caused by the loss of institutional knowledge. During the investigations, some maintenance needs were identified and will be addressed by the end of FY 2021. At the end of FY 2021, investigations, maintenance, and archiving activities will be complete. Remnants of test activities found at sites include craters, mud pits, debris, and open boreholes. Open boreholes are being plugged and abandoned in accordance with state regulatory standards. Other issues are being addressed in accordance with land owner requests and preferences as well as state regulations. Archiving activities include the development of project summaries identifying key operational details and current condition to allow site managers to be easily briefed. The LM experience at non-nuclear Plowshare and Vela Uniform sites applies to other programs where there is the potential for liability associated with the non-nuclear aspects of nuclear programs. This may include support activities or early phases of planned nuclear projects. Preserving institutional knowledge enables land managers to adequately address any concerns associated with operations and lowers risk. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2024

Results of an In-Field Validation Exercise in Support of Wide-Area Environmental Sampling

The National Nuclear Security Administration’s (NNSA) Office of Nonproliferation and Arms Control (NA-24) is evaluating Wide-Area Environmental Sampling (WAES) as an additional safeguards verification tool for the International Atomic Energy Agency to detect undeclared nuclear activities. The NNSA is evaluating strategies for conducting a generic WAES campaign, the cost of a WAES campaign, and the effect of technological advancements that have occurred since the last major WAES review in 1999. Until now, the NNSA effort has focused on tabletop exercises (TTXs) in which high-performance computing allows for advanced modeling and simulation efforts to be applied to the WAES question. Although the modeling and simulations used in the TTXs are extremely valuable, field campaigns are still needed to validate the assumptions that underpin the models and the modeling process itself. During a 7 week period beginning in May 2023 and ending in June 2023, which included 4 weeks of active field collections, a multilaboratory team conducted its first in-field validation exercise. Prior to the in-field exercise, abbreviated TTXs were conducted to estimate the performance of all collection systems to be used during the field test. These TTXs guided the selection of materials to be released and the placement of the collection system. Based on these determinations, materials were procured to use in the field test, and an injection/release system was designed, built, and installed at the test facility. Background samples were collected during weeks one and four, and environmental collections against active releases were conducted during weeks two and three. The goals of this validation exercise included a demonstration of (1) the ability to provide controlled releases of particulates of surrogate materials, (2) the fielding and operation of collection systems (including deposition and active air collectors), and (3) the flexibility to revise equipment and campaign plans in the field. This paper presents the results and preliminary conclusions for this initial validation test. Based on these results, subsequent field campaigns are anticipated and will include the addition of other released materials.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2020

An Overview of Nanomaterials for Environmental Remediation Applications

The environmental remediation capabilities of nanoparticles were reviewed and evaluated. Nanoparticles (NPs) have been used to remediate various forms of environmental contamination. Various materials, morphologies, and conditions are required to remediate different contaminants. Nanoparticles may have benefits and/or limitations compared with traditional remediation methods. New techniques are being applied to mitigate the limitations of NPs. Nanomaterials are a promising technology for the environmental remediation. NPs have been used for the remediation of aqueous and atmospheric contaminants. Nanoparticles have been used to sequester contaminants toxic to human and environmental health. Various materials, morphologies, and conditions are necessary for the remediation of different contaminants. The remediation of heavy metals is of significant concern. Contaminants may be remediated by means of sorption or reduction. The remediation capability of nanoparticles is promising due to their high surface area and reactivity. Reaction kinetics are, therefore, notably fast. These characteristics make NPs attractive for environmental remediation. Various NPs have been used as sequestering agents for environmental contaminants. NPs have been used to remediate heavy metals as well as organic contaminants. Technical Objectives: Assess viability of nanoparticles (NPs) for environmental remediation; Review benefits and limitations of NPs; Design future experiments to test remediation capabilities of NPs. Future Plans: Create NP filters for remediation - Grow Au NPs on Stainless Steel Wool: Stainless steel wool has many defects and crevices allowing the Au NPs to grow on the surface; Stainless steel wool will not react with the heavy metal contaminants tested; NPs are embedded, so they do not have to be removed from solution. Test sorption capabilities with heavy metal contaminants in aqueous solution. Benefits of Gold NPs: Corrosion/oxidation resistant; Exhibit visible/near IR plasmon resonance; Can be synthesized by solution chemistry: cost efficient and easily scalable. Surfactants: Used to lower surface energy and prevent aggregation; Sodium citrate: anionic surfactant (-); Cetyltrimethylammonium bromide (CTAB): cationic surfactant (+); Ionic surfactants create charged NPs; Charged NPs can be used to sequester ionic contaminants (eg. heavy metals)

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2022

Calendar Year 2021 Underground Test Area Annual Sampling Letter Report Nevada National Security Site, Nevada (Rev. 1) WITH ROTC-1

This calendar year (CY) 2021 annual sampling letter report presents Plan implementation and a summary of field activities, sampling methods, well completion diagrams, and analytical laboratory results from sampling of wells on Pahute Mesa. The CY 2021 letter report also presents data from samples collected in CY 2019. These CY 2019 results were not reported in previous sampling reports because they were not available from the specialized laboratory (Lawrence Livermore National Laboratory [LLNL]) at the time of the previous reports’ publication.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2021

Towards testing the theory of gravity with DESI: summary statistics, model predictions and future simulation requirements

Shortly after its discovery, General Relativity (GR) was applied to predict the behavior of our Universe on the largest scales, and later became the foundation of modern cosmology. Its validity has been verified on a range of scales and environments from the Solar system to merging black holes. However, experimental confirmations of GR on cosmological scales have so far lacked the accuracy one would hope for — its applications on those scales being largely based on extrapolation and its validity there sometimes questioned in the shadow of the discovery of the unexpected cosmic acceleration. Future astronomical instruments surveying the distribution and evolution of galaxies over substantial portions of the observable Universe, such as the Dark Energy Spectroscopic Instrument (DESI), will be able to measure the fingerprints of gravity and their statistical power will allow strong constraints on alternatives to GR. In this paper, based on a set of N-body simulations and mock galaxy catalogs, we study the predictions of a number of traditional and novel summary statistics beyond linear redshift distortions in two well-studied modified gravity models — chameleon f(R) gravity and a braneworld model — and the potential of testing these deviations from GR using DESI. These summary statistics employ a wide array of statistical properties of the galaxy and the underlying dark matter field, including two-point and higher-order statistics, environmental dependence, redshift space distortions and weak lensing. We find that they hold promising power for testing GR to unprecedented precision. The major future challenge is to make realistic, simulation-based mock galaxy catalogs for both GR and alternative models to fully exploit the statistic power of the DESI survey (by matching the volumes and galaxy number densities of the mocks to those in the real survey) and to better understand the impact of key systematic effects. Using these, we identify future simulation and analysis needs for gravity tests using DESI.

79 ASTRONOMY AND ASTROPHYSICS↗
DOE OSTI2022

Ultrasonic Testing of Mechanical Changes in a Water-Filled Pipe with Multi-Mode and Broadband Signals and Two-Level Compensation

Ultrasonic testing (UT) has been widely used for the Nondestructive Evaluation (NDE) of pipes due to its many favorable characteristics. However, one of the main challenges in the general use of UT for real-world pipelines is the sensitivity of this method to environmental and operational condition changes. This paper proposes a new UT method with enhanced compensation for environmental effects and operational condition changes. In particular, the effectiveness of the new method is tested in the presence of temperature variations, and changes in water flow rate inside a stainless-steel pipe. The proposed UT method uses multi-mode and broadband guided ultrasonic waves in the pipe walls, excited and received by single-element ultrasonic sensors that are spatially separated, forming a measurement zone between any pair of such transmit and receive sensors. Amplitude changes, time shifts, and frequency content variations in the ultrasonic signal due to temperature changes and water flow are evaluated and compensated for reliable UT of mechanical changes in the pipe. It is observed that spurious effects of water flow on ultrasonic response, if not properly compensated, can dominate over effects due to actual mechanical changes, but such liquid-boundary effects can be compensated effectively by the proposed time- and frequency-filtering method.

47 OTHER INSTRUMENTATION↗
DOE OSTI2022

Smart detection of indoor occupant thermal state via infrared thermography, computer vision, and machine learning

The ability to measure occupants’ thermal state in real time will enable major advances in the control of air conditioning systems. This study proposes predicting occupant thermal state by a combination of infrared thermography, computer vision, and machine learning. The approach (1) uses cheek, nose, and hand temperatures because they are least subject to blockage by hair, glasses, and clothing; (2) measures the distribution of skin temperatures within geometrically defined sub-areas of the face and hand; and (3) uses temperature differences within and between these areas to eliminate the effects of calibration drift that are unavoidable in thermal infrared (TIR) cameras. Two series of tests were conducted, respectively in an outdoor carport and an indoor environmental chamber, collecting a total of 48,422 sets of cheek, nose, and hand skin temperatures using a TIR camera and computer-vision technology, coupled with 715 subjective responses of thermal sensations. To predict occupant thermal state, Random Forest classification models were built using either absolute skin temperatures (the maximum and median temperatures of cheek and hand segments, and the temperature of the central spot on the nose), or intra- and inter-segment temperature differences of cheeks, hands, and nose. These measurements were found to accurately predict occupant thermal state. Using the maximum and median temperatures for cheek and nose, or for cheek and hand, predicts thermal state with an accuracy of 92–96%. In conclusion, using only the intra- and inter-segment temperature differences from cheek and nose is 83% accurate; adding the hand temperature differences increases the accuracy to 96%.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2021

Benzo[a]pyrene (BaP) metabolites predominant in human plasma following escalating oral micro-dosing with [ 14 C]-BaP

Benzo[a]pyrene (BaP) is formed by incomplete combustion of organic materials (petroleum, coal, tobacco, etc.). BaP is designated by the International Agency for Research on Cancer as a group 1 known human carcinogen; a classification supported by numerous studies in preclinical models and epidemiology studies of exposed populations. Risk assessment relies on toxicokinetic and cancer studies in rodents at doses 5–6 orders of magnitude greater than average human uptake. Using a dose–response design at environmentally relevant concentrations, this study follows uptake, metabolism, and elimination of [ 14 C]-BaP in human plasma by employing UPLC - accelerator mass spectrometry (UPLC-AMS). Volunteers were administered 25, 50, 100, and 250 ng (2.7–27 nCi) of [ 14 C]-BaP (with interceding minimum 3-week washout periods) with quantification of parent [ 14 C]-BaP and metabolites in plasma measured over 48 h. [ 14 C]-BaP median T max was 30 min with C max and area under the curve (AUC) approximating dose-dependency. Marked inter-individual variability in plasma pharmacokinetics following a 250 ng dose was seen with 7 volunteers as measured by the C max (8.99 ± 7.08 ng × mL -1 ) and AUC0-48hr (68.6 ± 64.0 fg × hr -1 × mL -1 ). Approximately 3–6% of the [ 14 C] recovered (AUC 0-48 hr ) was parent compound, demonstrating extensive metabolism following oral dosing. Metabolite profiles showed that, even at the earliest time-point (30 min), a substantial percentage of [ 14 C] in plasma was polar BaP metabolites. The best fit modeling approach identified non-compartmental apparent volume of distribution of BaP as significantly increasing as a function of dose (p = 0.004). Bay region tetrols and dihydrodiols predominated, suggesting not only was there extensive first pass metabolism but also potentially bioactivation. AMS enables the study of environmental carcinogens in humans with de minimus risk, allowing for important testing and validation of physiologically based pharmacokinetic models derived from animal data, risk assessment, and the interpretation of data from high-risk occupationally exposed populations.

59 BASIC BIOLOGICAL SCIENCES↗
DOE OSTI2020

Characterizing photovoltaic backsheet adhesion degradation using the wedge and single cantilever beam tests, Part II: Accelerated tests

Photovoltaic (PV) backsheets provide critical moisture, mechanical, and electrical insulation to the backside of PV modules, but their continued functionality depends upon their ability to remain well adhered over years of harsh environmental exposure. A study of adhesive strength was conducted on several PV backsheet types exposed to indoor accelerated weathering. Two adhesion tests – the wedge test and single cantilever beam test – were used to measure adhesion energy in four backsheets: two with fluoropolymer-based outer (airside) layers – polyvinyl fluoride (PVF), polyvinylidene fluoride (PVDF) – and two with non-fluoropolymer-based outer layers–polyamide (PA) and polyethylene terephthalate (PET). The effects of changes in temperature, ultraviolet (UV) irradiance, relative humidity, and a periodic water spray were studied. The PET-, PVF- and PVDF-based backsheets all showed instances of debonding in an adhesive layer, which is commonly reported. Furthermore, for the PA-, PET-, and PVDF-based backsheets, adhesion energy dropped fairly rapidly with exposure, reaching very low levels by 4000 h. The PVF-based backsheet was relatively robust to weathering. Pull-off of an outer chalking layer in the PA- and PET-based backsheets suggested a sensitivity to UV. Adhesion in these two backsheets was also highly sensitive to changes in moisture level. Changes in UV irradiance and temperature did not show a statistically significant effect on adhesion loss for the exposure levels used. The present work is part of a two-part adhesion study on both field-weathered and indoor-exposed backsheets, and forms a basis for understanding adhesion degradation across a variety of backsheet types and degradation factors.

14 SOLAR ENERGY↗
DOE OSTI2020

Failure modes of protection layers produced by atomic layer deposition of amorphous TiO 2 on GaAs anodes

Amorphous titanium dioxide (a-TiO 2 ) films formed by atomic layer deposition can serve as protective coatings for semiconducting photoanodes in water-splitting cells using strongly alkaline aqueous electrolytes. Herein, we experimentally examine the mechanisms of failure for p + -GaAs anodes coated with a-TiO 2 films (GaAs/a-TiO 2 ). Galvanic displacement of exposed GaAs by Au allowed imaging of pinholes in the a-TiO 2 coatings, and enabled collection of quantitative and statistical data associated with pinhole defects. A combination of imaging, electrochemical measurements, and quantitative analyses of corrosion products indicated that extrinsic pinholes were present in the a-TiO 2 films before electrochemical operation. During electrochemical operation these pinholes led to pitting corrosion of the underlying GaAs substrate. The dominant source of pinholes was the presence of atmospheric particulate matter on the GaAs surface during deposition of the a-TiO 2 layer. The pinhole density decreased substantially when the thickness of the a-TiO 2 coating increased beyond 45 nm, and approached zero when the thickness of the film exceeded 112 nm. The density of pinholes in films thinner than 45 nm decreased when the a-TiO 2 coating was deposited in an environmentally controlled cleanroom. Pinhole-free GaAs/a-TiO 2 devices were also tested via chronoamperometry to quantify the rate of pinhole formation during electrochemistry. The time-to-failure increased with thickness, suggesting that the failure mechanism may involve diffusion or migration through the film. However, other mechanisms may also contribute to the degradation of thicker films (>112 nm). Nevertheless, as previously hypothesized, extrinsic pinhole defects formed during deposition and testing control the short-term protective performance of the a-TiO 2 film for GaAs anodes evolving O 2 from water.

25 ENERGY STORAGE↗
DOE OSTI2023

A new approach to the design of surface subsystems of polymeric insulators for HV and MV apparatus under AC voltage

The design of high voltage and medium voltage AC and DC standoff insulators, and, in general, of insulation systems where surface and interface properties are predominant factors, is based on specifications and standards that rely upon long-term experiences and lab testing. Surface insulating properties depend on electrical and thermal stresses, besides environmental factors, and the inception of extrinsic ageing phenomena, such as partial discharges, can be already a cause of reduced reliability and premature failure (for organic insulating materials). An innovative approach, based on field simulation, discharge modelling, and partial discharge inception measurements is presented by the authors, which can establish a solid basis to optimise insulation design for any type of supply voltage waveform. This method, the three-leg approach, is applied here to a cable system under AC sinusoidal voltage, but it can work for any type of insulation system, such as bushings, switch gears, transformers, rotating machines, and power electronics boards.

42 ENGINEERING↗