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Results for “solar module durability”

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 55 records · Page 3
All sourcesNASA NTRSDOE OSTI
DOE OSTI2026

Eutectic Processing of Semiconductor Colloidal Nanocrystals for Energy Applications

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

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
NASA NTRS1985

Demonstrated results of welded and soldered interconnections

Solar cell modules with welded and soldered interconnections were constructed using a flexible substrate material. These modules were thermally cycled between approx. 80 deg C at rates 100 cycles/day to demonstrate survivability under simulated low Earth orbit (LEO) temperature conditions. The modules, cycled in an inert atmosphere, show durability for 36,000 cycles.

Hart, R. E., Jr.↗
NASA NTRS1986

Flat-plate solar array project. Volume 7: Module encapsulation

The objective of the Encapsulation Task was to develop, demonstrate, and qualify photovoltaic (PV) module encapsulation systems that would provide 20 year (later decreased to 30 year) life expectancies in terrestrial environments, and which would be compatible with the cost and performance goals of the Flat-Plate Solar Array (FSA) Project. The scope of the Encapsulation Task included the identification, development, and evaluation of material systems and configurations required to support and protect the optically and electrically active solar cell circuit components in the PV module operating environment. Encapsulation material technologies summarized include the development of low cost ultraviolet protection techniques, stable low cost pottants, soiling resistant coatings, electrical isolation criteria, processes for optimum interface bonding, and analytical and experimental tools for evaluating the long term durability and structural adequacy of encapsulated modules. Field testing, accelerated stress testing, and design studies have demonstrated that encapsulation materials, processes, and configurations are available that meet the FSA cost and performance goals.

Cuddihy, E.↗
DOE OSTI2025

Nanoscopic cross-grain cation homogenization in perovskite solar cells

Multiscale cation inhomogeneity has been a major hurdle in state-of-the-art formamidinium–caesium (FA–Cs) mixed-cation perovskites for achieving perovskite solar cells with optimal power conversion efficiencies and durability. Although the field has attempted to homogenize the overall distributions of FA–Cs in perovskite films from both plan and cross-sectional views, our understanding of grain-to-grain cation inhomogeneity and ability to tailor it—that is, spatially resolving the FA–Cs compositional difference between individual grains down to the nanoscale—are lacking. Here we reveal that as fundamental building blocks of a perovskite film, individual grains exhibit cationic compositions deviating from the prescribed ideal composition, severely limiting the interfacial optoelectronic properties and perovskite layer durability. This performance-limiting nanoscopic factor is linked to thermodynamic-driven morphological grooving, leading to a segmented surface landscape. At the grain triple junctions, grooves form nanoscale groove traps that hinder the mixing of solid-state cations across grains and thus retard inter-grain FA–Cs mixing. By rationally modulating the heterointerfacial energies, we reduced the depth of these nanoscale groove traps by a factor of three, significantly improving cation homogeneity. Perovskite solar cells with shallower nanoscale groove traps demonstrate enhanced power conversion efficiencies (25.62%) and improved stability under various standardized international protocols. In conclusion, our work highlights the significance of resolving surface nano-morphologies for homogeneous properties of perovskites.

77 NANOSCIENCE AND NANOTECHNOLOGY↗
DOE OSTI2025

Durability Research Is Pivotal for Perovskite Photovoltaics

Metal halide perovskite solar cells have shown promising power conversion efficiencies, but commercialization requires that decent durability is also demonstrated. Under normal operation, solar cells are subject to a complex combination of stressors, such as visible light, ultraviolet light, heat, humidity, mechanical stress and electric potential, which complicates the understanding of failure mechanisms. Existing stress tests do not act as a time machine. In new materials systems such as perovskite photovoltaics, the tests have no known relationship to field service. In this Perspective we recommend following a durability learning cycle that interleaves photovoltaic module engineering with field testing; accelerated testing; and preconditioning and performance engineering. We advocate for field testing to demonstrate real-world performance and identify field-relevant failure modes, and urge the community to develop accelerated and qualification tests that account for device metastability, variations in material composition and different/various processing methods. In conclusion, these practices are more difficult, but more important, than the simple pursuit of higher initial efficiencies.

14 SOLAR ENERGY↗
DOE OSTI2026

Solar-Tracker Diffuse-Response Algorithm for Balancing Energy Gain and Mechanical Wear in Photovoltaic Systems

Single-axis solar tracking maximizes photovoltaic energy production under clear-sky conditions; however, its effectiveness decreases under cloudy and overcast skies, where diffuse irradiance dominates and the optimal module orientation changes. Conventional tracking algorithms either neglect sky conditions or rely on simplified diffuse-response strategies that may trigger frequent tracker repositioning under variable cloud cover, leading to increased mechanical wear with marginal energy gains. This work proposes an enhanced diffuse-response tracking algorithm that explicitly accounts for both the intensity and temporal persistence of cloudiness. By requiring overcast conditions to persist for a minimum duration before reorienting the tracker to a diffuse-stow position, the proposed approach reduces unnecessary movements while preserving the benefits of diffuse-response operation. The algorithm is evaluated through numerical simulations based on historical meteorological data and validated using field measurements on monofacial and bifacial photovoltaic strings. The results show that the proposed strategy reduces excess tracker movement from 114% to 0.16% while maintaining nearly the same energy yield. Compared to a conventional diffuse-response algorithm, the associated energy reduction is minimal (≈0.17%) relative to the ≈0.37% yield gain observed at the studied location. These findings demonstrate that incorporating cloudiness duration enables a practical compromise between energy performance and tracker durability, particularly for monofacial photovoltaic systems.

14 SOLAR ENERGY↗
NASA NTRS1980

Use of Glass Reinforced Concrete (GRC) as a substrate for photovoltaic modules

A substrate for flat plate photovoltaic solar panel arrays using a glass fiber reinforced concrete (GRC) material was developed. The installed cost of this GRC panel is 30% less than the cost goal of the Near Term Low-Cost Flat Plate Photovoltaic Solar Array Program. The 4 ft by 8 ft panel is fabricated from readily available inexpensive materials, weighs a nominal 190 lbs., has exceptionally good strength and durability properties (rigid and resists weathering), is amenable to mass production and is easily installed on simple mountings. Solar cells are encapsulated in ethylene/vinyl acetate with Tedlar backing and Korad cover film. The laminates are attached to the GRC substrate with acrylic transfer tape and edge sealed with silicone RTV adhesive.

Eirls, J. L.↗
DOE OSTI2026

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.

14 SOLAR ENERGY↗
NASA NTRS1984

The kinematic Stirling engine as an energy conversion subsystem for paraboloidal dish solar thermal plants

The potential of a suitably designed and economically manufactured Stirling engine as the energy conversion subsystem of a paraboloidal dish-Stirling solar thermal power module was estimated. Results obtained by elementary cycle analyses were shown to match quite well the performance characteristics of an advanced kinematic Stirling engine, the United Stirling P-40, as established by current prototypes of the engine and by a more sophisticated analytic model of its advanced derivative. In addition to performance, brief consideration was given to other Stirling engine criteria such as durability, reliability, and serviceability. Production costs were not considered here.

Bowyer, J. M.↗
DOE OSTI2024

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↗
DOE OSTI2024

PV Reliability and Resilience in Challenging Climates

Challenging climates for Photovoltaics are usually based on climate classification. However, extreme weather events such as high wind, flooding, large hail, extreme snow etc. have become more ubiquitous globally. To study the impact of extraordinary weather events on PV reliability we used two of the largest databases in the USA. First, the National Oceanic and Atmospheric Administration (NOAA) database on extreme weather and secondly, the PV Fleet Data Initiative where we have collected high-resolution PV performance data of more than 8 gigawatts or about 6-7% of all commercial and utility systems in the USA. We analyzed almost 200 systems between 2008-20022 that were immediately impacted by these weather events. The immediate impact (outages) was determined to be about 1% of or a median of approximately 3 days of annual lost production. However, the risk these events pose is exemplified by a long tail where 0.4 % of all systems lost more than 2 weeks annual production. We also found a threshold for high wind (90 km/hr) and hail (25mm), above which we observed significantly higher degradation implying long-term damage to the systems. In addition, we are using satellite imagery to quantify visible damage to PV plants. Finally, we share module, design and installation lessons from some observed case studies to improve extreme weather resilience for PV power systems.

degradation↗
DOE OSTI2024

The "PVLib" of Degradation: PVDeg

The Photovoltaic (PV) industry constantly aims for lower costs through higher-efficiency cells, improved module designs, and improvements in durability. This leads to the use of new materials, designs, and manufacturing processes, and not always with a sufficient amount of durability testing. To help drive down costs there is a desire to create modules that will last for up to 50 years of service life. To accomplish this, every degradation mode and mechanism must be identified and either eliminated or otherwise mitigated. This involves the extrapolation of laboratory results to the field conditions. There is a need to organize the existing degradation data into an accessible format and to provide industry relevant tools for extrapolation from laboratory to field conditions. While the basic equations used to model degradation are sometimes very simple, the full analysis involves calculations are cumbersome but ubiquitous for many degradation processes. A simplified, modeling framework to accomplish these repetitive processes will facilitate the analysis to help researchers keep up with the rapid pace of technological changes. In this talk, we will describe our progress creating the open-source tool PVDeg. This tool can be used to search for and analyze degradation information and extrapolate PV module performance and durability to field exposure. PVDeg simplifies many of the common foundational computational operations for obtaining meteorological data and using it to generate a model of the PV deployment. This prediction tool repository also contains various degradation models as well as a library of material parameters suitable for estimating the durability assessment of materials and components. We use an integration pipeline approach that allows us to leverage weather data from the National Solar Radiation Database, and other weather sources, to perform geospatial degradation analysis in the US and worldwide. We hope to become a repository that can be used for weathering and degradation analysis for various applications beyond the PV industry. During the talk, we will provide the PVPMC attendees the opportunity to interact with the tool via a Google Collab tutorial they can run on their phones or laptops.

durability↗
DOE OSTI2026

>24% screen printed Cu contacted n-TOPCon solar cells with successful implementation of LECO process

In this paper, we report the successful fabrication of >24.0 % efficiency n-TOPCon Si solar cells with screen-printed, fire-through Cu contact to n-TOPCon on the rear side and Ag contacted boron emitter on the front side by implementing optimized firing and LECO conditions. The highest efficiency (24.3%) Cu contacted n-TOPCon cell in this study showed excellent cell performance parameters with V oc >730 mV, J sc of 41.1 mA/cm 2 and FF of 80.8%, resulting in an absolute efficiency gap of 0.2% between Cu-contacted and fully Ag contacted n-TOPCon cells (24.5%). The mini-module fabricated with the Cu contacted n-TOPCon cell showed excellent reliability and durability of open-circuit voltage (V oc ), pseudo fill factor (pFF) and efficiency after prolonged damp-heat tests. Such high efficiency screen printed Cu contacted n-TOPCon cells provide unique opportunity to replace very expensive Ag contact on n-TOPCon with cheaper screen printable Cu metal pastes.

14 SOLAR ENERGY↗
DOE OSTI2024

DuraMAT: Building a Consortium to Accelerate the Photovoltaic Module Reliability Learning Cycle

Durable and reliable photovoltaic (PV) modules are critical to enabling an efficient transition to sustainable energy generation. The rate at which new module designs and materials are developed and deployed currently outpaces the rate at which we can identify failure mechanisms and understand degradation rates. Increasing the service life of PV modules, and our ability to predict performance over time, requires more durable materials and designs, better durability testing, more extensive material characterization, robust modeling, and methods to cross-examine historical performance data to extract meaningful results. This is a multidisciplinary challenge that requires expertise from a broad range of fields and, therefore, benefits significantly from a collaborative approach. In this Perspective, we outline the approach taken by the Durable Module Materials Consortium (DuraMAT), present a few case studies where our approach was successful, and provide an outlook on where this approach might be applied as the PV technology landscape continues to rapidly evolve. Published by the American Physical Society 2024

14 SOLAR ENERGY↗
NASA NTRS1983

Qualification testing and electrical measurement experience: A manufacturer's view

ARCO Solar's experiences as a participant in an industry-utility-government environmental qualification team examining photovoltaic devices are discussed. Included is an assessment of the applicability, completeness and appropriateness of the testing procedures and of the acceptance criteria for megawatt-sized procurements for utilities. Like the stand-alone users, the utility industry is interested in obtaining low costs, but additional concerns exist related to reliability and durability, safety, grounding and overall system criteria including performance prediction (related to output power acceptance testing), power quality and dispatchability. For purposes of this first major purchase of photovoltaic modules and panels by the utility industry, there was a carry-over of the JPL specifications. The need exists for futher development, assessement, and selection of qualification and testing standards and evaluation criteria specifically addressing these additional concerns for utility-connected PV power-plant applications.

Arnett, J. C.↗
DOE OSTI2024

Tough Break: Many Factors Make Glass Breakage More Likely

We have seen cases of glass in PV modules breaking differently, and more often, than it did five years ago. There have been many changes to PV module design and materials in that time. But there is probably no single change that is responsible for the problem. Here we summarize the current thinking on PV glass breakage in utility-scale power plants. We share insights from multiple still-running projects at NREL.

14 SOLAR ENERGY↗
NASA NTRS1974

Skylab mission report, third visit

An evaluation is presented of the operational and engineering aspects of the third Skylab visit, including information on the performance of the command and service module and the experiment hardware, the crew's evaluation of the visit, and other visit-related areas of interest such as biomedical observations. The specific areas discussed are contained in the following: (1) solar physics and astrophysics investigations; (2) Comet Kohoutek experiments; (3) medical experiments; (4) earth observations, including data for the multispectral photographic facility, the earth terrain camera, and the microwave radiometer/scattermometer and altimeter; (5) engineering and technology experiments; (6) food and medical operational equipment; (7) hardware and experiment anomalies; and (8) mission support, mission objectives, flight planning, and launch phase summary. Conclusions discussed as a result of the third visit to Skylab involve the advancement of the sciences, practical applications, the durability of man and systems in space, and spaceflight effectiveness and economy.

Source record↗
DOE OSTI2024

Assessment of Accelerated Stress Testing Data for Silicon Photovoltaics Using Tensor Decomposition Methods

The photovoltaic (PV) industry is simultaneously targeting long warranties and new materials/designs for high-energy-yield modules, requiring an advanced methodology to forecast long-term durability of products with un-proven materials combinations. Extended, sequential, and combined stress testing methods are gaining popularity for assessing durability of PV modules/materials beyond the early-stage mortalities. Importantly, multiple degradation mechanisms can proceed simultaneously, and their separate contributions to the overall power loss should ideally be quantified. This work examines the use of data-driven tools towards developing a strategy for faster learning cycles in accelerated stress testing.

accelerated stress testing↗