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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 415 records · Page 23

DC-Ripple-Energy Adaptive-Minimization (DREAM) Modulation Scheme for a High Power Density Inverter

The DC bus capacitor is one of the major power-density and reliability hurdles of electric drive systems. It is hard to shrink because it is constrained by the DC bus RMS ripple current, which is only load dependent. A dual-inverter based segmented drive can reduce the ripple current by ~50% compared to a non-segmented case. This paper analyzes the origin of this ripple current and points out the path for minimization. An optimal DC-ripple-energy adaptive-minimization (DREAM) modulation method is proposed to further reduce the ripple current. It is observed in experimental results that the proposed method can achieve additional 38% reduction over the traditional segmented drive system.

Xue, Lincoln↗

A fast method for optical simulation of flood maps of light-sharing detector modules

Optical simulation of the detector module level is highly desired for Position Emission Tomography (PET) system design. Commonly used simulation toolkits such as GATE are not efficient in the optical simulation of detector modules with complicated light-sharing configurations, where a vast amount of photons need to be tracked. Here, we present a fast approach based on a simplified specular reflectance model and a structured light-tracking algorithm to speed up the photon tracking in detector modules constructed with polished finish and specular reflector materials. We also simulated conventional block detector designs with different slotted light guide patterns using the new approach and compared the outcomes with those from GATE simulations. And while the two approaches generated comparable flood maps, the new approach was more than 200–600 times faster. The new approach has also been validated by constructing a prototype detector and comparing the simulated flood map with the experimental flood map. The experimental flood map has nearly uniformly distributed spots similar to those in the simulated flood map. In conclusion, the new approach provides a fast and reliable simulation tool for assisting in the development of light-sharing-based detector modules with a polished surface finish and using specular reflector materials.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗

Surface Stress Characterization and Trends in Thermally Strengthened Photovoltaic Module Glass

Simultaneous changes in photovoltaic (PV) module architecture-such as increased area, replacing the polymeric backsheet with a glass backsheet, and reducing glass thickness from 3.2 to 2.0 mm-have resulted in a novel failure called spontaneous glass breakage. Spontaneous glass breakage results in front and/or rear glass failure without any obvious cause. The resulting low-energy fracture patterns have raised concerns about the thermal strengthening in 2.0-mm glass. We present validation of a nondestructive method for measuring the glass surface stress in PV modules. We use a scattered light polariscope to examine the glass properties of 11 modules from 6 solar fields, with and without spontaneous glass breakage. Based on a Mann-Whitney test p-value of 1.4 x 10-6, we conclude that there is a correlation between lower surface stress and susceptibility to spontaneous breakage. A Kendall's Tau test p-value of 2.0 x 10-4 indicates a correlation between increased module area and lower surface stress. We find that 2.0-mm glass can be, and often is, fully tempered (surface stress ≥69 MPa), but inspecting the fracture pattern is not a reliable way to assess the amount of thermal strengthening. A combination of factors, not just surface stress, influences glass breakage.

14 SOLAR ENERGY↗

High Temperature Copper Metallization: Demand, Hurdles and Reliability

As newer cells structures come online, the pressing need to replace silver in the metallization pastes has renewed interest in alternative technologies employing base metals. Copper typically leads the charge with its abundance and lower cost but has faced numerous obstacles from relatively higher oxidation and diffusion rates which can damage the lifetime of the devices. In this study, a low-cost alternative to silver metallization pastes has been shown on PERC cells. The screen printable copper paste can be fired in air at temperatures >500 degrees C, and the impact of processing conditions and equipment on the performance and reliability of 274 cm2 cells have been evaluated. Through damp heat testing of micro-modules using 16 cm2 cells, routes that can lead to both the failure and success of durable contacts have been demonstrated.

copper↗

Performance of a Natural Gas Solid Oxide Fuel Cell System With and Without Carbon Capture

The fuel cell program at the United States Department of Energy (DOE) National Energy Technology Laboratory (NETL) is focused on the development of low-cost, highly efficient, and reliable fossil-fuel-based solid oxide fuel cell (SOFC) power systems that can generate environmentally-friendly electric power with at least 90 percent carbon capture. NETL’s SOFC technology development roadmap is aligned with near-term market opportunities in the distributed generation sector to validate and advance the technology while paving the way for utility-scale natural gas (NG)- and coal-derived synthesis gas-fueled applications via progressively larger system demonstrations. The present study represents a part of a series of system evaluations being carried out at NETL to aid in prioritizing technological advances along research pathways to the realization of utility-scale SOFC systems, a transformational goal of the fuel cell program. In particular, the system performance of utility-scale NG fuel cell (NGFC) systems with and without carbon dioxide (CO2) capture is presented. The NGFC system analyzed features an external auto-thermal reformer (ATR) feeding the fuel to the SOFC system consisting of planar anode-supported SOFC with separated anode and cathode off-gas streams. In systems with CO2 capture, an air separation unit (ASU) is used to provide the oxygen for the ATR and for the combustion of unutilized fuel in the SOFC anode exhaust along with a CO2 purification unit to provide a nearly pure CO2 stream suitable for transport for usage in enhanced oil recovery operations or for storage in underground saline formations. Remaining thermal energy in the exhaust gases is recovered in a bottoming steam Rankine cycle while supplying any process heat requirements. A reduced order model (ROM) developed at the Pacific Northwest National Laboratory (PNNL) is used to predict the SOFC performance. The ROM, while being computationally effective for system studies, provides other detailed information about the state of the stack, such as the internal temperature gradient, generally not available from simple performance models often used to represent the SOFC. Such additional information can be important in system optimization studies to preclude operation under off-design conditions that can adversely impact overall system reliability. The NGFC system performance was analyzed by varying salient system parameters, including the percent of internal (to the SOFC module) NG reformation—ranging from 0 to 100 percent—fuel utilization, and current density. The impact of advances in underlying SOFC technology on electrical performance was also explored.

solid oxide fuel cell (SOFC), natural gas fuel cel↗

Foreword: Special Section on Multiphysics Aspects of Power Electronics Packaging—Power Die, Power Module, and Converter Level: Part 2

Power electronics are increasingly being used to condition electricity for a wide array of applications, such as transportation (on land, air, and water), data centers, radio frequency, directed energy, wind, solar, and grid-tied applications. Here, to increase power density, performance, efficiency, and reliability-as well as to reduce cost-innovations and developments are needed in the multiphysics packaging of power electronics at a die, module, and converter level. This includes fundamental R&D related to emerging high-voltage, high-temperature, and high-switching-frequency power electronics, packaging materials, thermal materials and interfaces, fluid-based thermal management technologies, reliability, condition monitoring, and prognostics. Latest developments in this area are published as a Special Section on Multiphysics Aspects of Power Electronics Packaging. The first part was published in the May 2024 issue of the IEEE Transactions on Components, Packaging and Manufacturing Technology (Volume 14, Issue 5). The second part of that Special Section is being published in this issue. A brief summary of the papers included in the second part are given below.

24 POWER TRANSMISSION AND DISTRIBUTION↗

The experiment filtering tool in the MACSENS workbench - 14341

The MACSENS (outils Moret d'Aide a la Caracterisation et aux etudes de SENSibilite) workbench is dedicated to the advanced validation work for criticality studies. The aim of this kind of tool is to determine the experiments from a validation database being the 'closest' to an application case and, from there, to evaluate a calculation bias with a related uncertainty. To achieve this goal, the MACSENS workbench relies on different kind of information stored in various databases depending on the origin of the data. Two main kinds of data can be identified. The first one concerns the data used to describe the experiments of the validation database (e.g. the inputs needed to perform a calculation). These values characterize the chemical and geometrical models. They can be considered as constant, as they do not vary once evaluated, and some of them can be from a non-numerical nature (reflector material for example...). The second kind of data gathers the results obtained with the use of a simulation code, such as reaction rates, fluxes and leakages, sensitivities, k{sub eff}, etc. These values depend on the version of the code and are purely numerical. In the early 2000's, regarding the increasing number of experiments evaluated in the ICSBEP handbook, the OECD/NEA (Organization for Economic Co-operation and Development/Nuclear Energy Agency), under the ICSBEP (International Criticality Safety Benchmark Evaluation Project) working group direction, decided to store such information in a database and to provide a software, called DICE (Database for the International Criticality safety benchmark Evaluation project), allowing users to search easily criticality experiments of interest. Up to now, more than 4400 critical or subcritical configurations have been compiled by ICSBEP, described and stored in the DICE database. Over time, a validation work has been done on the data, with the participation of IRSN, and a quality assurance policy has been defined. For these reasons, the DICE database is highly reliable. These features were fundamental for the MACSENS developers, who were looking for a database containing descriptive data of the experiments included in the MORET code validation database. The paper describes the solution chosen by IRSN to take advantage of the DICE database content and to overcome the DICE limits. It also explains the quality assurance policy applied to guaranty the reliability of the stored data. It will also discuss the use of the experiment-filtering module of the MACSENS workbench to select a set of experiments and to examine numerical parameter trends for an application case. (authors)

42 ENGINEERING↗

Defining the 50-Year Module: Luck, Design, or Both?

Poster presenting a new Duramat project that will develop a science-based definition of a "50-year solar panel" by combining reliability data, climate risks, design choices, and long-term cost analysis. The work aims to clarify what is needed to enable longer-lasting, high-value solar systems.

14 SOLAR ENERGY↗

Starting dynamics of a linear-cavity femtosecond Mamyshev oscillator

Mamyshev oscillators can generate high-power femtosecond pulses, but starting a mode-locked state has remained a major challenge due to the suppression of continuous-wave lasing. Here, we study the starting dynamics of a linear Mamyshev oscillator designed to generate high-power femtosecond pulses while avoiding component damage. Reliable starting to stable mode-locking is achieved with a combination of modulation of the pump power and shifting of a filter passband. The starting process is automated, with full electronic control. The laser delivers 21-nJ pulses that are dechirped to 65 fs in duration outside the cavity.

Chen, Yi-Hao (ORCID:0000000244001983)↗

A Methodology to Evaluate the Grid Reliability Impact of Oscillations Induced by Large Loads

The rapid growth of hyperscale AI data centers is bringing renewed attention to the reliability risk that sustained forced oscillations pose to bulk power systems, with cyclic computational workloads emerging as a new forcing source. Unlike the broadband, stochastic disturbances from traditional industrial loads such as arc furnaces, AI training and inference facilities can inject large active power swings concentrated at specific frequencies over extended durations - characteristics that existing grid planning practices do not account for. While the North American Electric Reliability Corporation (NERC) has recognized this gap and called for system-level studies of large load interconnections, no standardized methodology exists to screen, simulate, and quantify these risks at the planning stage. This report presents the Risk Assessment Tool for Large Load-induced Events (RATLLE), a Python-based, publicly available script suite developed at the Pacific Northwest National Laboratory to evaluate bulk power system reliability risks from data center-induced oscillations. RATLLE implements a three-module workflow: a screening module that identifies vulnerable interconnection locations and excitable system modes; a simulation module that models cyclic data center load behavior using a commercial positive sequence simulation platform; and an analysis module that computes risk metrics and generates interactive visualization dashboards. The risk metrics, formulated around simulation observables, map oscillation impacts to a three-stage severity scale spanning latent equipment fatigue through imminent cascading failure. The methodology is demonstrated on two Western Electricity Coordinating Council (WECC) system models: a publicly available 240-bus reduced representation and a detailed 2031 Heavy Winter planning case. Case studies illustrate that even modest 50 MW forced oscillations at resonant frequencies can produce wide-area power swings, N-1 security constraint violations, and cascading generator trips through protection actions - outcomes that would not occur under normal operating conditions without oscillations present. The results underscore the need for standardized oscillation impact assessment in large load interconnection studies and provide a reproducible, extensible framework for utilities to adopt or customize within their existing planning workflows.

Biswas, Shuchismita↗

Review of Ultrafast Switching Power Modules: Trends, Challenges, and Technical Solutions

Benefiting from the superior properties of wide-bandgap semiconductor materials, wide-bandgap power devices demonstrate exceptional switching performance, enabling more efficient and compact power electronics systems. However, ultrafast switching poses challenges to the reliability of the system in terms of severe oscillations and voltage overshoot, electromagnetic interference, and increased risk of partial discharge. By developing advanced power module packaging for fast-switching power devices, the above-mentioned challenges can be mitigated at the packaging level, enabling the full utilization of the fast-switching capability of wide-bandgap devices. Meanwhile, such technology also lays the groundwork for packaging next-generation power devices with even higher blocking voltage and faster switching speed. In this paper, a comprehensive review of ultrafast switching power modules has been made, including the benefits and status of ultrafast switching power modules, challenges brought by ultrafast switching, and promising technologies to address these challenges. In addition, future development trends and research gaps are also discussed in this paper. Furthermore, this review can serve as a reference for future wide-bandgap power module packaging design.

24 POWER TRANSMISSION AND DISTRIBUTION↗

Motivation, benefits, and challenges for new photovoltaic material & module developments

Abstract In the last decade and longer, photovoltaic module manufacturers have experienced a rapidly growing market along with a dramatic decrease in module prices. Such cost pressures have resulted in a drive to develop and implement new module designs, which either increase performance and/or lifetime of the modules or decrease the cost to produce them. In this paper, the main motivations and benefits but also challenges for material innovations will be discussed. Many of these innovations include the use of new and novel materials in place of more conventional materials or designs. As a result, modules are being produced and sold without a long-term understanding about the performance and reliability of these new materials. This has led to unexpected new failure mechanisms occurring few years after deployment, such as potential induced degradation or backsheet cracking. None of these failure modes have been detected after the back then common single stress tests. New accelerated test approaches are based on a combination or sequence of multiple stressors that better reflect outdoor conditions. That allows for identification of new degradation modes linked to new module materials or module designs.

Oreski, G. (ORCID:0000000342239047)↗

Solar Photovoltaics Resilient Fasteners Levelized Cost of Energy (LCOE) Tool

Solar photovoltaics (PV) module fasteners are one of the most common structural failure points on PV systems, particularly in high winds and coastal areas with ocean spray. Some fastener types have been shown to survive these conditions at higher rates than others. The fastener type, material, quantity, and placement all impact performance. Fasteners that fail less often typically have a higher upfront cost, but this investment can pay off in savings from less frequent torque audits (which reduces O&M costs), reduced system damage, and decreased system downtime. We developed an Excel-based tool to evaluate different module fasteners for a PV system - either a new or retrofit project - and compare differences in upfront and outyear costs to determine the expected life cycle costs and simple payback periods of different fastener options. The tool is site-specific, with inputs including system attributes (such as system size, location, price of power) and fastener attributes (such as design, washer type, nut type, use of locking hardware, materials, installation time, and torque audit requirements). A baseline fastener scenario can be compared to up to four proposed fastener scenarios. In addition to presenting expected life cycle cost implications of the different fastener options, the tool produces results showing the reductions in outyear costs needed to offset any initial cost premiums for more reliable fasteners across four categories: preventative O&M, avoided damage, reduced downtime, and reduced insurance premiums. These numbers can serve as decision aids for users when considering fastener options on new or existing projects. This poster will present the tool, methodology, and scenarios using example sites to highlight the tool capabilities and how it can inform different fastener decisions on different projects. Future work includes incorporating lifetime expected damage costs by embedding damage function curves that the authors are developing from field data.

14 SOLAR ENERGY↗

PV Reliability -- Where We've Been and Where We're Going

The photovoltaic (PV) industry has demonstrated impressive progress toward deploying hardware with excellent quality. As module prices drop and designs are squeezed to reduce cost of materials and processing, how will this affect the failures that are seen in the field?

14 SOLAR ENERGY↗

Investigation of Correlation between Field Performance and Indoor Acceleration Measurements of Potential Induced Degradation (PID) for c-Si PV Modules

The correlation between outdoor field testing and indoor chamber measurement for potential-induced degradation in crystalline silicon PV modules is unclear. The motivation of this work is to build up a direct comparison and investigate the correlation between indoor and outdoor performance. First of all, four PID indoor tests were defined from basic to premium, based on the difficulty of the test. Six groups of modules were designed and fabricated in Trina Solar, with different grades of PID resistance from weak to strong. The outdoor field test systems were built in three different climates: tropical, subtropical, and semi-arid climates in Singapore, Changzhou (China) and Golden (CO, USA) respectively, in a collaborative testing campaign involving Trina, SERIS and NREL. The system in Golden has been on-sun for more than 13 months where <4% power loss which includes PID and other reliability losses was detected and power loss of <2% is shown for all six groups of modules after 21 weeks in the field in the subtropical climate in Changzhou. However, PID of 23% was observed after 18 weeks in Singapore for the most PID-susceptible module, while the other PID module types showed degradation of only less than 5%.

14 SOLAR ENERGY↗

PV backsheets survey protocol: A framework for geo-spatial field surveys for bulk material characterization and reliability analysis applied across 41 PV systems

As widespread adoption of photovoltaic (PV) technologies continues, understanding the lifetime of modules is paramount to the viability of the industry as an environmentally conscious alternative to traditional energy generation. Although power degradation can affect the total energy production of a module over its lifetime, module safety failures necessitate the removal of a module leading to a loss of not only the particular asset, but the earning potential of the device. Therefore, it is critical to ensure that the components that provide essential safety functions for PV module operate for their entire rated lifetime. PV backsheets provide necessary electrical insulation to the completed device and failure of this component is cause for a immediate removal of the module. Degradation of the PV module backsheet has led to module safety failures in large-scale installations, costing millions of dollars in damages and lost potential revenue. The spatio-temporal degradation of fielded PV modules is important to study in order to identify which modules within installations are experiencing the greatest exposure conditions and in turn have the highest chance of failure. This paper describes a comprehensive field survey protocol developed for monitoring PV module backsheet performance using solely non-destructive methods in commercial PV fields. The protocol establishes a field naming convention, sampling method, data handling requirements, and measurement procedures. By ensuring consistent data collection practices, the field survey protocol enables research groups to obtain data of uniform quality on backsheet performance over multiple years and locations. In this study, the developed protocol was implemented at forty-one PV sites. Eight different types of airside layer backsheet materials including poly(vinylidene fluoride) (PVDF), acrylic PVDF, poly(tetrafluoroethylene-co-hexafluoropropylene-co-vinylidene fluoride) (THV), poly(vinyl fluoride) (PVF), poly(ethylene terephthalate) (PET), fluoroethylene vinyl ether (FEVE), polyethylene naphthalate (PEN), and glass were identified using attenuated total reflection Fourier transform infrared (ATR-FTIR) spectroscopy. The field survey results show that the spatial distribution of degradation indicators are non-uniform within a particular module, individual site, and across site locations. The degradation of PV modules increased in severity for modules mounted at the edge of rows (across a field) and near the junction box (within a module). This study demonstrates the sensitivity of material performance to exposure length across different materials and climates.

14 SOLAR ENERGY↗

The Role of Reliability and Durability in Photovoltaic System Economics

This presentation was delivered as a webinar to members of the Durable Modules Materials Consortium (led by NREL) on February 11, 2019. We are now preparing it for posting to the DuraMAT website. The presentation offered an overview of how NREL's technoeconomic analysis helps to guide DuraMAT's work. Specifically, the presentation offers several examples of how analysis helps answer the question 'what is the value of solving a particular problem?'

14 SOLAR ENERGY↗

A rapid and convenient method for the preparation of thermochromic VO{sub 2} thin films

Highlights: • A simple and efficient route has been developed for the preparation of VO{sub 2} thin films. • VO{sub 2} films annealed at high enough crystallization temperature were obtained and analyzed. • Excellent optical modulation both in the visible and near-infrared region has been achieved in the prepared VO{sub 2} film. - Abstract: The annealing temperature for the preparation of VO{sub 2} films with sputtering method have always been applied in the range of 300–500 °C. Herein, a simple and efficient route has been developed for the preparation of VO{sub 2} thin films through the thermal oxidation of sputtered vanadium film at 585 °C. Structural, morphological, elemental analysis and thermochromic properties of synthesized VO{sub 2} films are reported. Different from the traditional sputtered VO{sub 2} films, large change of transmittance has been found in the visible region during phase transition. The present work shows the feasibility to fabricate reliably reproduced high quality VO{sub 2} films with reversible phase transition and excellent optical modulation both in the visible and near-infrared region.

36 MATERIALS SCIENCE↗