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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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DOE OSTI2024

Bifacial Photovoltaic Module Degradation Dynamics

In a comprehensive study conducted at NREL's 75 kW bifacial single-axis-tracked field, accelerated degradation was observed in four out of five bifacial silicon photovoltaic (PV) module technologies when compared to their monofacial counterparts. Root cause analysis of accelerated bifacial degradation involved various analytical tools and techniques. This included employing RdTools to identify rates of power loss, conducting measurements on fielded and control modules using infrared imaging, electroluminescence (EL) and photoluminescence (PL), quantum efficiency (QE) analysis, IV-curves assessment, as well as utilizing handheld Raman and reflectance measurement targeted at anti-reflective coating. Most cases pointed to carrier lifetime degradation causing Voc loss and simultaneous Isc loss. In some cases, Isc further decreases likely due to optical effects from encapsulant degradation. The outcomes and methodologies employed in this investigation are documented in this publication. This study's significance is further emphasized by placing the findings within the broader context of the performance and degradation of various bifacial systems, as identified in the PV Fleets data.

bifacial↗
DOE OSTI2023

DuraMAT FY 2022 Annual Report: Towards Predicting Lifetime

The Durable Module Materials Consortium (DuraMAT) launched in November 2016 with five years of funding from the U.S. Department of Energy s (DOE's) Solar Energy Technologies Office (SETO). The program renewed in 2022 for an additional 6 years. DuraMAT is a multi-lab consortium led by the National Renewable Energy Laboratory, with Sandia National Laboratories (Sandia) and Lawrence Berkeley National Laboratory (LBNL) as core research labs. DuraMAT's overarching goal is to accelerate a sustainable, just, and equitable transition to zero-carbon electricity generation by 2035. We work in partnership with our 22-member industry advisory board and the technical management team at SETO. DuraMAT transitioned from our first five-year program into a new six-year program in 2022. It was a very busy year; DuraMAT wrapped up projects from DuraMAT 1 and kicked off new laboratory-led projects for DuraMAT 2. This transition brings new goals and a renewed focus on accelerating the energy transition by improving photovoltaic (PV) module reliability.

accelerated stress testing↗
DOE OSTI2021

Cracked Solar Cell Performance Depends on Module Temperature

When cells in a crystalline silicon photovoltaic module crack, packaging materials hold the fragments together. Changes in module temperature cause cell fragments to move, allowing cracked metallization to lose and regain contact. We intentionally cracked cells in commercial PV modules and characterized the modules’ temperature-dependent electroluminescence (EL) response. Here we show that (1) metallization makes contact across cracks in a way that is temperature dependent and (2) this contact is not a function of temperature, but is hysteretic. We expect that any electro-optical characterization made at a single temperature will be misleading as to the effects of cracked cells at different temperatures. And we expect that a single temperature sweep cannot fully characterize the temperature dependence of electro-optical performance of modules with cracked cells.

crack↗
DOE OSTI2021

A Circularity Assessment for Silicon Solar Panels Based on Dynamic Material Flow Analysis

This paper examines the impacts of design, operational, and end-of-life (EOL) waste pathways’ parameters on material circularity in silicon solar photovoltaic (PV) modules. Dynamic material flow analysis (DMFA) quantifies time-series material flows through systems’ life cycle stages to identify hotspots of waste generation, estimate resource needs in the future, and guide sustainable material management. We introduce a DMFA framework based on U.S. electricity demand for the period 2000-2100 to assess stocks and flows of bulk PV materials (i.e., solar glass and aluminum frames). We apply the model to a range of scenarios to understand how material demands depend on selected PV-related parameters, different material circularity strategies, and recent module design trends (e.g., bifacials, large-format-high power modules). Our results enable advanced planning for future materials needs and provide insight into potential opportunities to minimize material waste.

circular economy↗
DOE OSTI2022

PV DMFA [SWR-21-105]

The Photovoltaic Dynamic Material Flow Assessment (PV DMFA) model (also referred to here as “The model”) is a computational framework written in Python based on utility-scale PV electricity generation to quantify time-series stocks and flows of PV materials primarily in crystalline silicon PV technologies. The model evaluates cradle-to-cradle life cycle of utility-scale solar PV systems in the United States in the period 2000-2100. PV DMFA serves as a sustainability analysis tool to assess the impacts of different material circularity practices (i.e., reduce, reuse/refurbish, remanufacture, and recycle), PV module design shifts and sensitivity of material processing and technology related parameters to material installations, waste creation and raw material depletion in PV material supply chains. This tool enables advanced planning for future material needs and informs sustainable pathways for PV material management in the circular economy. This tool could be helpful to a wide range of stakeholders; Particularly, researchers and manufacturers looking for technoeconomic and/or environmental life cycle analysis (LCA) feedback for renewable energy (RE) systems.

Khalifa, SherifA.↗
DOE OSTI2019

Proceedings of the 2019 PV Reliability Workshop, 26-28 February 2019, Lakewood, Colorado

NREL hosts an annual Photovoltaic Reliability Workshop (PVRW) so solar technology experts can share information leading to the improvement of PV module reliability. Such improvement reduces the cost of solar electricity and promotes investor confidence in the technology - both critical goals for moving PV technologies deeper into the electricity marketplace. This document collects the presentations and posters from the 2019 PV Reliability Workshop, which was hosted by NREL from Tuesday, February 26, to Thursday, February 28, 2019.

14 SOLAR ENERGY↗
DOE OSTI2020

Observations of PV Systems Post-Hurricane

NREL's observations of post-hurricane photovoltaic (PV) systems were shared with PV reliability researchers during the Photovoltaic Reliability Workshop held in Lakewood, Colorado the week of February 26, 2018. NREL hosts an annual Photovoltaic Reliability Workshop (PVRW) so that solar technology experts can share information leading to the improvement of PV module reliability. Such improvement reduces the cost of solar electricity and promotes investor confidence in the technology - both critical goals for moving PV technologies deeper into the electricity marketplace. This presentation is intended to share real world examples of PV survivability during and after Hurricanes Irma and Maria in 2017.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗
DOE OSTI2021

A Comparison of Emerging Nonfluoropolymer-Based Coextruded PV Backsheets to Industry-Benchmark Technologies

As the photovoltaic (PV) industry is rapidly expanding around the world, there has been an increasing interest in extending the lifespan of PV modules. Concern has also emerged regarding the recyclability of modules and their component materials, including fluoropolymer-based backsheets. Laminated polyethylene-terephthalate (PET) core backsheets have traditionally been used in the PV industry, but new, coextruded polyolefin (PO) backsheets show promise as an improved alternative. In this work, minimodule and coupon samples of seven different backsheets (made of layers including contemporary PET and fluoropolymers, novel PO, and polyamide materials) were run through hygrometric- or UV photolytic-accelerated aging to identify and better understand each material's degradation modes and the backsheets' field reliability. In addition to the artificial aging, the natural weathering methods used in this article are described. The comprehensive set of chemical, mechanical, and structural characterizations at intermittent read points in this article is presented, including: visual appearance and color; gloss; mechanical tensile testing; I-V performance; electroluminescence (EL) imaging; dielectric breakdown; Fourier-transform infrared-chemical structure; X-ray-polymer structure; and differential scanning calorimetry-crystalline content. After 4000 h of aging, a strong correlation occurs between initial physical characteristics (mechanical tensile test) and operating performance (EL and I-V characteristics).

14 SOLAR ENERGY↗
DOE OSTI2022

Characterization of Contact Degradation in Crystalline Silicon Photovoltaic Modules (Final Technical Report)

In this project, the aim was to develop highly-automated metrology methods that can provide more insights into degradation and failure, while still relying on the types of measurements the PV industry and RD communities are comfortable with (e.g., I – V and EL). In particular, our focus was to develop techniques to better understand contact and interconnect degradation in crystalline silicon (c-Si) PV modules and apply those techniques to conventional and emerging c-Si cell architectures and cell interconnection technologies.

14 SOLAR ENERGY↗
DOE OSTI2025

Exploring Capability of Multimodal Foundation Model for Image-based Fault Detection of Photovoltaic Modules

Multimodal Foundation Model (MFM), like ChatGPT and Gemini, have emerged as powerful tools for their exceptional natural language processing capabilities and their emerging potential in image analysis. This paper investigates the application of MFMs for photovoltaic (PV) fault detection through image analysis, focusing on ChatGPT 4.0 and Gemini 1.5 Pro. Three types of PV images and the corresponding common PV faults are detected: bird droppings using visible images, cell cracks via electroluminescence (EL) images, and hotspots using infrared (IR) images. Among the two models, Gemini 1.5 Pro demonstrated superior performance, achieving near-perfect results with an average F1 score of 0.97, consistently outperforming ChatGPT 4.0 in accuracy and reliability. Unlike traditional machine learning (ML) models, MFMs can operate in a zero shot manner that does not require additional training by the user, and the input images are not limited by size, angle, scope, or PV technology. The strong adaptability and user-friendliness make MFM a promising tool for analyzing PV images and advancing health monitoring for PV modules.

Li, Baojie↗
DOE OSTI2019

Measured and Calculated DC Arc-Flash Incident Energy in a Large-Scale Photovoltaic Plant

There is a growing amount of high-power dc equipment being deployed, including solar photovoltaic (PV) plants, but very few studies have measured and quantified dc arc-flash risks. Most dc arc-flash literature is based on the theory and, when their theoretical calculations are applied to real-world conditions, can significantly deviate from actual measured values. For PV, the nonlinearity of the power source (i.e., PV modules) creates an additional level of uncertainty for theoretical approaches. This paper quantifies the thermal hazards from arc flash in a real-world 1000-kWdc PV plant by measuring arc current, arc voltage, and incident energy (IE) and then compares results against existing IE models. The study reveals that none of the available models adequately represent real-world hazards. It is also found that a PV source acts as a sustainable constant-current source during an arcflash event. As a result, this paper is an important first step toward developing an improved model that more accurately assesses dc arc-flash risk in a PV system.

14 SOLAR ENERGY↗
DOE OSTI2021

Employing Fracture Statistics to Track Cell Reliability Through Module Fabrication

In this work we demonstrate how fracture statistics may be employed to track cell reliability through module fabrication steps. We were able to detect how cell cutting equipment could reduce cell fracture strain by 25 % as well as increase its variability. A smaller reduction was found to result from the ribbon soldering operation, and all cells measured were weaker when strained in an orientation perpendicular to the gridlines. Cell fracture measurements were found to be consistent with the number of cracked cells experienced in full sized modules exposed to mechanical loading. A structural mechanics model was created to elucidate how the requisite fracture strain is developed in a cell encapsulated within a PV module and demonstrates that this strain decreases more than 50 % from its center to edge when placed within the inner loading span of four-point flexure. The associated implications on the apparent cell strength is examined with an effective volume treatment.

41 EE - Solar Energy Technologies Office (EE-4S)↗
NASA NTRS1993

Computation of photovoltaic parameters under lunar temperature variation

Photovoltaic (PV) arrays with regenerative-fuel-cell energy storage is a prime, power-system candidate for lunar photo-power. The PV module performance decreases at higher temperatures. Surface temperature variations of the moon are extreme, the maximum (noon) temperature being 384 K. The present work utilizes detailed computations of photovoltaic parameters with computer program developed earlier for the computation of optimum bandgaps of single- and two-junction solar cells at different temperatures, and calculates the power output of single and two-junction solar modules under different configurations which constitutes an improvement over the assumption of a linear variation of efficiency with temperature. The program also calculates the necessary PV-array size to satisfy stipulated levels of day- and night-time power consumption.

Dhere, Neelkanth G.↗
DOE OSTI2021

Employing Fracture Statistics to Track Cell Reliability Through Module Fabrication

In this work we demonstrate how fracture statistics may be employed to track cell reliability through module fabrication steps. We were able to detect how cell cutting equipment could reduce cell fracture strain by 25 % as well as increase its variability. A smaller reduction was found to result from the ribbon soldering operation, and all cells measured were weaker when strained in an orientation perpendicular to the gridlines. Cell fracture measurements were found to be consistent with the number of cracked cells experienced in full sized modules exposed to mechanical loading. A structural mechanics model was created to elucidate how the requisite fracture strain is developed in a cell encapsulated within a PV module and demonstrates that this strain decreases more than 50 % from its center to edge when placed within the inner loading span of four-point flexure. The associated implications on the apparent cell strength is examined with an effective volume treatment.

14 SOLAR ENERGY↗
DOE OSTI2019

Development of Combined and Sequential Accelerated Stress Testing for Derisking Photovoltaic Modules

This talk reviews sequential and combined accelerated stress tests of the past decade that have been shown to better replicate degradation mechanisms seen in the field, that single-factor steady-state tests have failed to reproduce. When designing stress tests for PV modules, it is shown, with examples, how it is beneficial to consider representation of the shipping module, the stress factors applied, and how the stress factors are sequenced or combined in the natural environment. Finally, current and future efforts to realize accelerated stress tests based on these concepts are discussed.

14 SOLAR ENERGY↗
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 OSTI2026

Do solar panels contain PFAS?

The presence and potential leaching of PFAS (Per- and Polyfluoroalkyl Substances) from solar panels are increasingly mentioned in news articles, raising public concerns. Such concerns may slow the adoption of photovoltaic (PV) technology, despite its central role in the renewable energy sector. The limited transparency from manufacturers about fluorinated materials used in PV modules, along with the scarcity of publicly available testing data, contributes to uncertainty and speculation. This perspective aims to clarify the current state of PFAS presence in solar PV. Although certain fluoropolymers are used in PV manufacturing, the scientific consensus on their toxicity indicates they should not be classified as PFAS. Portraying fluoropolymers as toxic PFAS unnecessarily amplifies concerns and unfairly undermines the perceived environmental sustainability of PV technology.

environmental impact↗
DOE OSTI2020

bifiPV2020 Bifacial Workshop: A Technology Overview

The virtual bifiPV Workshop was held in July 2020 to provide the solar industry with a forum for sharing and discussing research into bifacial photovoltaic (PV) technology. This report outlines major insights from the workshop to give the reader an overview of the latest developments in bifacial PV technology worldwide, from the lab to the field. Citations are drawn from this workshop unless otherwise noted, with all proceedings available online at bifipvworkshop. com. Presentations for the bifiPV2020 Workshop focused on the following areas: bifacial power plant modeling and simulation, albedo improvements, the development of encapsulants, the durability and reliability of current bifacial technologies, performance comparisons between glass-glass and glass-transparent backsheet configurations, the future of passivated emitter and rear contact (PERC) solar cells, and the growing adoption of n-type solar cells. With 650 GW total PV installed worldwide and 1 TW to come very soon, PERC is now the standard PV cell type produced en masse. However, it is already reaching 23% efficiency, the upper limit for this type of technology. PV modules breaking the 0.5-kW barrier are starting to appear, and the costs of standard PERC technology are already below 0.2 USD/Wp. In 2019, five GW of bifacial PV were installed worldwide. In 2020, the majority of bifacial installations are expected to be located in the United States, China, and Middle East and North Africa (MENA) states. N-type bifacial technologies are becoming increasingly viable and have huge potential to dominate the market in the coming years. With bifacial technology mounted on horizontal single-axis trackers (HSAT), bids below 10 USD/MWh will soon be observed in the MENA region, and later in Chile and the United States. Factory audits and reliability testing can reduce field failures by helping buyers to select producers that follow rigorous quality assurance and quality control processes.

14 SOLAR ENERGY↗