FY 2018 DuraMAT Annual Report
This report summarizes the progress and successes of the Durable Module Materials Consortium in FY 2018.
14 SOLAR ENERGY↗
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Results for “Module Reliability”
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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A New Approach to Robot Motor Control
This essay details the motor control improvements to Fermilab's Remote Viewing Robot (RVR). It is a robot tasked with remotely investigating issues within the accelerator tunnels at Fermilab. Initially controlled by a single Raspberry Pi that housed all the robot s operations, the RVR will now use a Raspberry Pi Pico W for its motor control. This was achieved using Pulse Width Modulation (PWM) to allow for precise speed and torque control for the robot. This enhances the robot s reliability. By addressing the challenge of navigating high radiation environments, the upgrade helps assist the RVR s goal of decreasing the need for human intervention in accelerator tunnels.
Lopez, Jacob↗
Challenges, Technological Pathways and Trade-Offs of Perovskite Solar Modules for Long-Term Operation
Perovskite solar modules (PSMs) have emerged as a promising photovoltaic technology due to their high efficiency, low fabrication cost and compatibility with lightweight and flexible applications. However, ensuring long-term reliable performance under real-world conditions remains a critical barrier to commercialization. PSMs degrade through mechanisms that differ substantially from those affecting established technologies such as silicon, particularly under environmental stressors like ultraviolet light, oxygen, temperature cycling and reverse bias. Here we provide an analysis of the degradation pathways specific to perovskite modules and discuss why standard accelerated tests often fail to predict outdoor performance. We conceptualize challenges across material, device and module levels and evaluate strategies to mitigate ion migration, interfacial breakdown and encapsulation failure. By highlighting the need for realistic testing protocols and durable materials, we propose a framework highlighting key challenges, technological pathways and the trade-offs required to extend perovskite module lifetimes towards long-term operation, aiming to guide the development of PSMs capable of a 30-year operational lifetime.
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Piezo-optomechanical cantilever modulators for VLSI visible photonics
Visible-wavelength very large-scale integration photonic circuits have a potential to play important roles in quantum information and sensing technologies. The realization of scalable, high-speed, and low-loss photonic mesh circuits depends on reliable and well-engineered visible photonic components. Here, we report a low-voltage optical phase shifter based on piezo-actuated mechanical cantilevers, fabricated on a CMOS compatible, 200 mm wafer-based visible photonics platform. We show linear phase and amplitude modulation with 6 V π cm in differential operation, −1.5 to −2 dB insertion loss, and up to 40 dB contrast in the 700–780 nm range. By adjusting selected cantilever parameters, we demonstrate a low-displacement and a high-displacement device, both exhibiting a nearly flat frequency response from DC to a peak mechanical resonance at 23 and 6.8 MHz respectively, which, through resonant enhancement of Q ∼ 40, further decreases the operating voltage down to 0.15 V π cm.
Dong, Mark↗
Degradation Science from Nanometers to Kilometers: A Pathway to Rapid Detection for Reliable Photovoltaics
Photovoltaics reliability for terrestrial applications has more than four decades of history and experience. International standards development has prevented many early life failures and must be continued in the future. Yet, as the module product development cycle is measured in mere months, additional investment in the fundamental degradation science and rapid detection should be developed. In this article, a brief strategy is provided addressing indoor accelerated, outdoor testing, and modeling efforts required to retain high reliability in the following decade.
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Development of highly efficient NEG pumping system for EBIS
Ultrahigh vacuum inside the ion trap volume is crucial for stable and reliable operation of an Electron Beam Ion Source (EBIS). We have developed and tested a compact linear pumping system based on the ZAO Non-Evaporable Getter (NEG) module with high pumping speed and enhanced sorption capacity for all active gases. Due to its minimal transverse dimensions, the system can be mounted adjacent to the ion trap inside a superconducting solenoid bore and will provide a pumping speed of the order of 1000 l/s for all active gases in that area. An externally supplied current (100 A DC) is used to heat the ZAO NEG up to 650 °C for more than 1 h, which is required for pump activation and/or reactivation cycles. The pumping system is being developed for use in the Extended EBIS Upgrade which is presently in progress at BNL. In conclusion, the design of the system and results of multiple tests are presented and discussed.
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3-Port Single-Stage PV & Battery Converter Improves Efficiency and Cost in Combined PV/Battery Systems
Due to impressive cost reductions in recent years, photovoltaic (PV) generation is now able to produce electricity at highly competitive prices, but PV’s inherent intermittency reduces the potential value of this energy. The integration of battery storage with PV will be transformational by increasing the value of solar. Utility scale systems will benefit by firming intermittency including PV ramp smoothing, grid support and load shifting, allowing PV to compete directly with conventional generation. For distributed grid-tied PV adding storage will reduce peak demand utility charges, as well as providing backup power during power grid failures. The largest long term impact of combined PV and battery systems may be for delivering reliable off-grid power to the billions of individuals globally without access to conventional power grids, or for billions more that suffer from daily power outages. PV module costs no longer dominate installed PV system costs. Balance-of-System (BOS) costs including the PV inverter and installation now contribute the majority of installed system costs. Battery costs are also dropping faster than installation and battery power converter systems. In each of these separate systems power converters have become a bottleneck for efficiency, cost and reliability. These bottlenecks are compounded in hybrid power conversion systems that combine separate PV and battery converters. Hybrid power conversion systems have required multiple power converters hardware units and multiple power conversion steps adding to efficiency losses, product and installation costs, and reliability issues. Ideal Power Converters has developed and patented a completely new theory of operation for electronic power converters using its indirect EnergyPacket Switching™ topology. It has established successful power converter products for both PV and battery systems, and its 3-Port Hybrid Converter is the first product to exploit the topology’s capability for the industry’s first single-stage multi-port hybrid power converter. This unique low cost approach eliminates the hybrid power conversion bottlenecks when integrating batteries into PV systems. As result this product will significantly accelerate market adoption of these systems.
14 SOLAR ENERGY↗
Electrically sensing Hachimoji DNA nucleotides through a hybrid graphene/ h -BN nanopore
We show that synthetic Hachimoji nucleobases can be reliably sensed by analysing the strength and duration of characteristic electrical signals generated when their presence in a nanopore modulates the conductance of an adjacent carbon wire.
59 BASIC BIOLOGICAL SCIENCES↗
Thermomechanical Degradation of Sintered Copper Under High-Temperature Thermal Shock
The need for reliable bonded interface materials is critical to realize the performance benefits of wide-bandgap devices in power electronics modules, especially in operating temperatures greater than 150 degrees C. In this paper, we investigate the thermomechanical performance of sintered copper (Cu) as a large-area attachment, bonded between Cu baseplates and active-metal-bonded substrates, under accelerated thermal shock (-40 degrees C to 200 degrees C) conditions. In the fabrication phase of the samples, we used different stencil patterns and found that the grid and stripe patterns resulted in a better outgassing of the residual organics during the sintering process, thereby ensuring a substantially improved bond quality compared to a full-area print. The paste consisted of Cu microflakes, and we performed sintering using a Budatec SP300 sintering press at 275 degrees C with 15 MPa of bonding pressure for 5 minutes in a nitrogen atmosphere. Under accelerated experiments, we monitored the degradation of the sintered Cu bond in the samples through C-mode scanning acoustic microscope (C-SAM) images. To quantify the defect percentage in C-SAM images, we investigated image denoising techniques to exclude the pattern prints. Finally, we cross-sectioned a sample and obtained scanning electron microscope images, which revealed adhesive fracture as the dominant failure mechanism.
ADVANCED PROPULSION SYSTEMS,INORGANIC, ORGANIC, PH↗
WISP: Watching grid Infrastructure Stealthily through Proxies (Final Technical Report)
The complex interdependencies of cyber systems (sensors and communications), physical grids and associated electricity market operations make protecting electric power grids a significant challenge. The energy sector is constantly under new, targeted, advanced and dangerous cyber-attacks that have the potential to result in the loss of human life. These threats are further exacerbated by our need to modernize the grid. One focus of cyber security research in smart grids is the securing of the SCADA system through advanced intrusion detection systems (IDS) and bad data detection algorithms in state estimation. These methods either require full knowledge of the system topology and parameters or fail to understand the physical behaviors under attack. WISP (Watching grid Infrastructure Stealthily through Proxies) is designed to provide additional protection to the power grid using only publicly available data. In particular, WISP exploits the spatio-temporal nature of the real time locational marginal prices (LMPs), in conjunction with other information such as bids, weather, outages and load data to analyze anomalous power pricing behaviors and then correlate those observations to localize regions of interest and identify potential cyber events. WISP is non-intrusive as the tool is deployed as a service in the Cloud or on premise and provides reliable information to system operators for enhanced situational awareness, without impeding energy delivery functions. The WISP technology comprises three modules: the data-driven anomaly detection core, the vulnerability and risk analysis and the root cause analysis. The data-driven anomaly detection core performs the tasks of feature selection, anomaly detection and attack region localization. The vulnerability and risk analysis module provides system level information of the vulnerable variables and times, assisting the operators in selecting monitoring and protection nodes. The root cause analysis module takes the detection results and identifies potential operational conditions that contribute to the detected anomalies. In Phase I, we have demonstrated the feasibility and effectiveness of WISP. We developed a realistic electricity market simulator capable of generating normal and attack market data under various operational conditions. We developed a series of cyber-attack detection and analysis algorithms and evaluated them under multiple data sources. Finally, we integrated all modules into an end-to-end software, providing functions for data management, data analytics and visualization. Specifically, we have achieved: (i) real-time data acceptance from external utility interfaces with >99% acceptance rate; (ii) high performance anomaly detection algorithms with >98% detection accuracy and <0.1% false alarm rate; and (iii) ultra-low computing delay <50 milliseconds. Additionally, our team developed algorithms to identify the vulnerable variables in electricity market operations and root cause analysis functions to identify major contributors to the price spikes. These ancillary modules are necessary when deploying WISP in real world industry environment. In Phase II, we have demonstrated the effectiveness of WISP software on realistic largescale power systems. We performed red team testing for the Phase I WISP software and identified software vulnerabilities and implemented corresponding mitigation solutions. We adapted the electricity market simulator for the Texas synthetic 2000-bus system and generated datasets for the false data injection attacks. We created database and visualization interfaces for the Texas system and the ISO New England system. We performed software optimization in terms of operation efficiency, computing speed and detection accuracy. Finally, we tested the software on the Texas system and the ISO New England system and evaluated the detection performance. Overall, we achieved above 89% detection rate, below 3% false alarm rate and below 37 seconds of end-to-end detection delay.
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THE CASE FOR PSR J1614–2230 AS A NICER TARGET
The Neutron star Interior Composition ExploreR (NICER) is expected to launch in 2017 and will gather X-ray data on neutron stars and other high-energy sources from a berth on the International Space Station. Its prime scientific goal is to measure the masses and radii of non-accreting neutron stars via fits to the energy-dependent waveforms produced by the rotation of hot spots on their surfaces. These measurements will provide valuable input to theoretical models of cold matter beyond nuclear density. Here we propose that PSR J1614−2230, despite its low count rate, is a promising source to observe with NICER. The reason is that XMM-Newton observations suggest that the fractional oscillation amplitude from PSR J1614−2230 could be high enough that this star cannot be very compact. We show that if we analyze 0.5 Ms of NICER data and 0.1 Ms of nearby off-source data and combine that analysis with the known mass of this star, we would find a robust lower limit to the radius with a statistical uncertainty of only ∼0.5−0.7 km. We also show that even if there is an unmodeled nonthermal component modulated at the pulsation frequency, good statistical fits could rule out significant biases. The low count rate will make reliable upper limits on the radius difficult, but the lower limit could rule out some equations of state that are currently being discussed. This analysis would require a good estimate of the non-source background, so Chandra observations of the vicinity of PSR J1614−2230 would be helpful.
79 ASTRONOMY AND ASTROPHYSICS↗
Low irradiance losses of photovoltaic modules
Here, the efficiency of a photovoltaic cell/module changes, as the intensity of incident irradiance decreases, in a non linear way and these changes are referred to as low irradiance losses. In this study data from field experiments, developed and organized by the National Renewable Energy Laboratory, are used to evaluate the low irradiance losses for a variety of module technologies. The results demonstrate that the ratio of the normalized power divided by the normalized short circuit current provide a good measure of the module's low light efficiency losses after both the maximum power and the short circuit current are adjusted for temperature effects. The normalized efficiencies determined through the field data, spanning for several months, are in good agreement with those determined under controlled conditions in a solar simulator. An analytical relation for the normalized efficiency is proposed based on existing formulation for the fill factor. Despite the approximate nature of the fill factor relation, this approach produces reliable results. It will be shown that a normalized efficiency curve can be used to extract information on the series and shunt resistances of the PV module and that the shunt resistance as a function of solar irradiance can be studied. Alternately, this formulation can be used to study the low irradiance losses of a module when the internal resistances are known.
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Solid-State Ultra-High Power Amplifier Modules Based on 100 V RF GaN Technology for LINACS Operating at 325 and 650 MHz
Purpose / objectives. This research project explores the groundwork for developing a new high efficiency, high reliability and cost effective radio frequency technology to be used in power sources for future linear accelerators. The frequencies of operation are 650 and 325 MHz, in use at Fermi National Laboratory. The technology can be extended to other frequencies. Brief Description. In this research work ultra-high power solid-state radio frequency sources are proposed operating at the stated frequencies of interest. The approach employs high voltage Gallium Nitride radio frequency transistors, operating at 100 V or higher, to achieve 5-kilowatts continuous-wave and 10 kilowatts pulse power level in a small form factor. The 5 kilowatts building block reduces the required number of combiners and related losses to achieve megawatts power levels. The design employs harmonic tuning techniques as used in class E, F and inverse F power amplifiers to achieve >70% efficiency and assembly techniques that overcome heat dissipation in such high power density systems. Solid-state technology achieves million hour operating lifetime compared to 10 – 100 thousand hours for incumbent technology based on vacuum tubes. Additionally, the modular approach afforded by a solid-state solution avoids complete system shutdown when one module fails. Overall, the approach reduces capital and operating cost. Research Results. During Phase I radio frequency Gallium Nitride building block transistors with 50 mm gate periphery were designed and built which achieve ~600 W continuous-wave when operating at 100 V bias and 1-kW pulsed when operating at 150V. This level of performance has been demonstrated with operation at 325 and 650 MHz, and in both cases measured efficiency exceeded 70%. Potential Applications. The technology identified as suitable for high efficiency power sources in particle accelerators can also be applied in megawatt class radars and several industrial, scientific and medical applications such as microwave sintering, radio frequency and microwave ablation, oil percolation, MRI scanners and Nuclear Magnetic Resonance spectrometers, etc… The high efficiency of these devices also translates into reduced electrical power consumption and lower cost of operation.
100 VDC↗
Advanced Micro- and Nanomaterials for Photovoltaics
Nanomaterials are becoming increasingly important photovoltaic technologies from absorbers to contacts. This book is dedicated to describing the novel materials and technologies for photovoltaics that derive from these new and novel approaches in solar technologies. We have collected a set of renowned experts in their respective fields as authors and their expertise covers a broad set of areas including novel oxides, quantum dots, CZTS and organic solar cells, as well as light management and reliability testing.
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Field Accelerated Stress Testing (FAST): Forecasting Plant-specific Failure Modes and Degradation Rates
Photovoltaic plant owners and insurance companies would like to be prepared for the forthcoming material warranty claims (material defects) and power warranty claims (degradation rate). To address the needs of these stakeholders, this presentation aims to introduce a new conceptual approach to perform accelerated testing right at the field of interest and it is called field accelerated stress testing (FAST). The primary goal of this presentation is to present a conceptual approach to forecast the field specific failure modes and degradation rates in advance by a factor of 2 to 5, right at the plant site using a few spare modules available at the plant location itself.
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Modeling of the effectiveness of novel edge seal designs for fast, low‐Cap‐Ex manufacturing
Abstract In the manufacturing of photovoltaic (PV) modules, the lamination process can take up to 20 min to complete. In this work, new lamination processes are being developed, and have been prototyped, which hope to be able to cut this time down to as little as 30 s. This could provide significant savings in the cost of lamination equipment, floor space, and energy. PV modules are expected to have a lifespan exceeding 20 to 30 years. For moisture‐sensitive PV technologies, the edge seal between the two layers of glass can be the weakest point of its reliability. There is an inherent challenge when evaluating edge seal materials due to their low permeation rates. As part of Colorado State University's Photovoltaic Research and Development 2, work at the National Renewable Energy Laboratory has developed models to evaluate edge seal configurations in glass‐glass PV modules. Here, this new manufacturing process is evaluated for long‐term moisture durability. Different edge seal design options within glass–glass PV modules are explored. Most of these designs are targeting a superstrate on glass configuration, e.g CdTe, but some designs could be used on conventional crystalline Si cells. Using COMSOL finite element simulation software, we investigated the edge seal and interlayer design configurations containing silicone perimeter edge adhesive, desiccated polyisobutylene‐based edge seal, air, and polyolefin while integrating climate conditions equivalent to a hot and humid environment such as Miami, Florida. We found optimized configurations that will allow the module to prevent moisture ingress over 50 years minimizing the amount of time and material used while utilizing polymers that are easily dispensed.
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A two-stage service restoration method for electric power distribution systems
Improving the reliability of power distribution systems is critically important for both utilities and customers. This calls for an efficient service restoration module within a distribution management system to support the implementation of self-healing smart grid networks. Although the emerging smart grid technologies, including distributed generators (DGs) and remote-controlled switches, enhance the self-healing capability and allow faster recovery, they still pose additional complexity to the service restoration problem, especially under cold load pickup (CLPU) conditions. Herein, a novel two-stage restoration framework is proposed to generate a restoration solutions with a sequence of control actions. The first stage generates a restoration plan that supports both the traditional service restoration using feeder reconfiguration and the grid-forming DG-assisted intentional islanding methods. The second stage generates an optimal sequence of switching operations to bring the outaged system quickly to the final restored configuration. The problem is formulated as a mixed-integer linear program that incorporates system connectivity, operating constraints, and the CLPU models. It is demonstrated that on using a multi-feeder test case, the proposed framework is effective in utilizing all available resources to quickly restore the service and generate an optimal sequence of switching actions to be used by the operator to reach the desired optimal configuration.
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Investigating the Crosslinking, Degradation, and Adhesion Behavior of Photovoltaic Encapsulants Under Thermal Accelerated Aging
Degradation of photovoltaic (PV) module encapsulant characteristics that lead to mechanical embrittlement and delamination remains a cause of failure in solar installations. A multiscale reliability model connecting the encapsulant mechanical and fracture properties to the degraded molecular structure and interfacial bonding to adjacent solar cell and glass substrates was previously published. The model, developed primarily for poly(ethylene-co-vinyl acetate) acetate (EVA) encapsulants, remains to be experimentally validated. Determining the degradation and crosslinking kinetics of alternative encapsulants, such as polyolefin elastomer (POE) and EVA/POE/EVA composites (EPE), can generalize the model. In this work, we subject fully cured EVA, POE, and EPE encapsulants to accelerated thermal aging to determine how high temperatures impact reaction kinetics. An increase in gel content (crosslinking) and decrease in crystallinity of the encapsulants under hot-aerobic (90 degrees C, 22% RH) and hot-anaerobic (90 degrees C, sealed in N 2 air) aging were observed, even in the absence of UV and crosslinking initiators. Fourier transform infrared spectroscopy (FTIR)-attenuated total reflectance analysis showed insignificant encapsulant degradation, demonstrating the critical role of UV and moisture in accelerating degradation. Adhesion testing performed on coupon-level specimens (cell/encapsulant/glass laminates) showed decreases in adhesion energy, Gc , from 5000 h of hot-dry (90 degrees C, ~1% RH) and hot-humid (90 degrees C, 60% RH) aging. POE coupons demonstrated the best stability, followed by EPE then EVA. For EVA and POE, hot-humid aged coupons experienced a larger decrease in Gc due to enhanced hydrolytic degradation. Hot-dry aging condition demonstrated that thermal degradation of the interface could be significant even if the encapsulant experiences negligible degradation in the absence of UV and elevated humidity.
accelerated aging↗