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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 OSTI2025

Q1-2024 Solar Cost Benchmarks

Each year, the U.S. Department of Energy’s (DOE) Solar Energy Technologies Office (SETO) and its national laboratory partners develop cost benchmarks for U.S. solar photovoltaic (PV) systems. These benchmarks track progress toward reducing solar costs and guide R&D priorities. Unlike typical studies that report only $/W, SETO uses intrinsic units (e.g., $/m² for mounting structures) to better capture how technology improvements such as module efficiency would impact system costs. This allows flexible modeling where inputs can vary significantly to assess cost sensitivity. Costs are reported in two ways: Minimum Sustainable Price (MSP): Long term, financially viable price under stable market conditions. Modeled Market Price (MMP): Actual market price, influenced by short term distortions such as tariffs or subsidies. Three national labs collect cost data from industry stakeholders, ensuring no duplication in outreach to stakeholders. Data reflects real transactions (primarily from Q1) and is weighted based on the number of sources per cost element. The PV System Cost Model (PVSCM) divides total installed system cost into eight categories: 1. Module (PV) 2. Inverter 3. Energy Storage System (ESS) 4. Structural BOS (SBOS) 5. Electrical BOS (EBOS) 6. Fieldwork 7. Office work 8. Other (developer/EPC costs) The first five are hardware costs, while the last three are soft costs. Each category includes fixed and variable cost components, where “size” depends on context (e.g., manufacturing capacity for modules vs. system capacity for installation costs). Variable costs are expressed using appropriate intrinsic units. The model reflects the owner’s upfront overnight capital cost, excluding tax credits. Tariffs and subsidies are treated as temporary market distortions affecting MMP but not MSP. PVSCM is implemented in Excel, where cost elements are aggregated into total system cost. Additional sheets handle unit conversions and operation & maintenance (O&M), with O&M costs levelized over the system’s lifetime.

14 SOLAR ENERGY↗
DOE OSTI2013

THE DECAYING LONG-PERIOD OSCILLATION OF A STELLAR MEGAFLARE

We analyze and interpret the oscillatory signal in the decay phase of the U-band light curve of a stellar megaflare observed on 2009 January 16 on the dM4.5e star YZ CMi. The oscillation is well approximated by an exponentially decaying harmonic function. The period of the oscillation is found to be 32 minutes, the decay time about 46 minutes, and the relative amplitude 15%. As this observational signature is typical of the longitudinal oscillations observed in solar flares at extreme ultraviolet and radio wavelengths, associated with standing slow magnetoacoustic waves, we suggest that this megaflare may be of a similar nature. In this scenario, macroscopic variations of the plasma parameters in the oscillations modulate the ejection of non-thermal electrons. The phase speed of the longitudinal (slow magnetoacoustic) waves in the flaring loop or arcade, the tube speed, of about 230 km s{sup -1} would require a loop length of about 200 Mm. Other mechanisms, such as standing kink oscillations, are also considered.

79 ASTRONOMY AND ASTROPHYSICS↗
DOE OSTI2017

A comparative energy analysis of three electrochromic glazing technologies in commercial and residential buildings

Here, we present a simulation study of three dynamic electrochromic window glazings, including a novel glazing capable of independently modulating its optical properties in both the visible and near-infrared spectrums. This capability allows this so-called “dual-band” technology to actively manage the solar heat and visible light transmitted into a building's interior, and creates the potential for heating, cooling, and lighting savings vis-à-vis competing window technologies. In this study EnergyPlus is used to simulate annual energy performance of the dual-band electrochromic (DBEC) glazing in three building types and 16 U.S. climate regions. The savings potential of DBEC windows are presented relative to a conventional electrochromic glazing; a visibly transparent, near-infrared switching electrochromic glazings; and several static alternatives, including ASHRAE 90-2010 standard compliant windows. Results indicate that the DBEC glazings are capable of outperforming alternatives in a diverse set of locations and building types, including both heating and cooling-dominated regions. Relative to code-compliant static windows, the DBEC is capable of achieving annual primary energy savings between 6 and 30 kW h/ft 2 of window area from reduced heating, cooling, and lighting demand. Relative to other advanced glazings, the savings are significantly lower, ranging from 0 to 1.2 kW h/ft 2 . Regional DBEC energy cost savings versus high performance static windows are presented to identify early potential market entries based on energy savings. Lastly, the impacts of widespread deployment of high-efficiency LED lighting on DBEC energy savings potentials are also presented.

14 SOLAR ENERGY↗
DOE OSTI2021

Electrolyte/Dye/TiO 2 Interfacial Structures of Dye-Sensitized Solar Cells Revealed by In Situ Neutron Reflectometry with Contrast Matching

The nature of an interfacial structure buried within a device assembly is often critical to its function. For example, the dye/TiO 2 interfacial structure that comprises the working electrode of a dye-sensitized solar cell (DSC) governs its photovoltaic output. These structures have been determined outside of the DSC device, using ex situ characterization methods; yet, they really should be probed while held within a DSC since they are modulated by the device environment. Dye/TiO 2 structures will be particularly influenced by a layer of electrolyte ions that lies above the dye self-assembly. We show that electrolyte/dye/TiO 2 interfacial structures can be resolved using in situ neutron reflectometry with contrast matching. Here, we find that electrolyte constituents ingress into the self-assembled monolayer of dye molecules that anchor onto TiO 2 . Some dye/TiO 2 anchoring configurations are modulated by the formation of electrolyte/dye intermolecular interactions. These electrolyte-influencing structural changes will affect dye-regeneration and electron-injection DSC operational processes. This underpins the importance of this in situ structural determination of electrolyte/dye/TiO 2 interfaces within representative DSC device environments.

14 SOLAR ENERGY↗
DOE OSTI2018

Multi-modal optimization of bismuth vanadate photoanodes via combinatorial alloying and hydrogen processing

Alloying transition metals, such as Mo, into BiVO 4 has emerged as the primary mechanism for improving carrier transport in this photoanode for solar fuels production. The present work establishes here the generality of improving photoelectrochemical performance through co-alloying with a transition metal electron donor and a structure-modulating rare earth. Further improvement for all such alloys is obtained by annealing the oxide materials in H 2 , ultimately producing photoanodes with above 3 mA cm -2 photocurrent density under AM 1.5G illumination, in the top tier of compact BiVO 4 films.

36 MATERIALS SCIENCE↗
DOE OSTI2020

Low Cost (CAPEX and variable): Tool design for cell and module fabrication with thin, free-standing silicon wafers

This project aimed to develop technologies that can potentially enable free-standing thin (<80 μm) wafer in today’s manufacturing lines with high production yield, and thereby reduce capex barriers of silicon photovoltaics cells and modules. One of the major benefits is that thin wafer dramatically reduces the amount of polysilicon required. As a result, it can lead to reduction in the capital expenditures associated with polysilicon refining and wafer fabrication, which together are more than half of the total capital expenditure to manufacture Si PV module. We focused our efforts on developing the tools needed to enable high yield fabrication of wafer, cell, and module with thin silicon wafers. However, as the wafer thickness reduces, the major challenge is that wafer breakage increases significantly. Three technological areas were explored in this project to improve the production yield of the silicon wafer, namely detection of edge cracks via dark-field near-infrared (NIR) scattering; (2) wafer handling using controlled temperature profiles; (3) manufacturable low-stress cell interconnection for multiwire. First, the formation of wafer cracks in submillimeter length is one of the reasons that causes wafer breakages. Crack detection tools are needed to enable us to locate and track the wafer crack during manufacturing, so that we can improve the process to reduce initialization. The state-of-the-art crack detection technique cannot fulfill the need for measuring submillimeter edge cracks detrimental for thin wafers. The prototype developed in this project demonstrates the scanning of microcracks near wafer edges. With a semi-automatic laboratory setup, the submillimeter cracks were reliably detected near the edges in multi-Si wafers. The smallest detectable crack is 200 µm in length in slow scans; and submillimeter cracks are detected in high-throughput scans at the scan speed of >0.5 m/s, which is compatible with the inline detection of a manufacturing line at least 1 sec/wafer. This detection limit is a significant advancement in comparison to the benchmarked industrial tool. Second, wafer handling with the well-controlled temperature profile was thought to be the solution to reduce crack initiation and propagation during the manufacturing. However, without crack detection being widely adopted in production line, we did not find a strong industrial pull toward this technology. We did an initial literature survey and then diverted our efforts to the other tasks. Third, the innovation on low-stress multi-wire interconnection tackles a fundamental problem in the standard interconnection scheme. The standard over-under “zig-zag” interconnection induces a significant amount of stress into the soldering point on the cell whenever PV module is under stress, e.g., thermal cycling, transportation, and installation. Therefore, the interconnection process was re-designed in this project to allow for significant movement between adjacent solar cells, e.g., due to thermal expansion, without building up stresses on the solar cells or solder joints. The new interconnection method with the cross-connect wire also simplifies the tabbing and stringing process by replacing the standard over-under method with an off-cell interconnect from top to bottom. A manual tabbing and stringing tool for this new process was prototyped in the lab to demonstrate the fabrication of this new interconnection design. During the test with brass sheets as our “testing cells”, it was found that the mechanical cycling test only broke the interconnection after more than 50,000 cycles, which is equivalent to more than 130 years of the day-and-night thermal cycles. Lastly, throughout the project, we continuously analyzed the PV market with techno-economic analysis to identify the opportunity for thin Si adoption. Even though the drastic cost reduction has already happened in the past five years, our analysis results indicated that we can still save quite significantly in both manufacturing cost and factory capex, Particularly, in order to grow the PV manufacturing capacity to multi-terawatt level, reducing the thickness of silicon wafer is one of the most effective ways to quickly reduce factory capex, and sustain the high growth rate. The technologies developed in this project are readily available to provide some assistances in tackling the production yield problem.

14 SOLAR ENERGY↗
DOE OSTI2020

Predicting Solar Plant Generation with Machine Learning Techniques

Accurately predicting power generation for PV sites is critical for prioritizing relevant operations & maintenance activities, thereby extending the lifetime of a system and improving profit margins. A number of factors influence power generation at PV sites, including local weather, shading and soiling losses, design of modules, DC mismatches, and degradation over time. Other external factors such as curtailment and grid outages can also have a notable impact on power generation. Machine learning techniques can be used to provide more accurate predictions of PV power production by accounting for important weather and climate information neglected by current industry methods. This article will cover the deficiencies of those methods and will show how machine learning can dramatically improve power generation predictions.

14 SOLAR ENERGY↗
DOE OSTI2016

A Nonrelational Data Warehouse for the Analysis of Field and Laboratory Data From Multiple Heterogeneous Photovoltaic Test Sites

A nonrelational, distributed computing, data warehouse, and analytics environment (Energy-CRADLE) was developed for the analysis of field and laboratory data from multiple heterogeneous photovoltaic (PV) test sites. This data informatics and analytics infrastructure was designed to process diverse formats of PV performance data and climatic telemetry time-series data collected from a PV outdoor test network, i.e., the Solar Durability and Lifetime Extension global SunFarm network, as well as point-in-time laboratory spectral and image measurements of PV material samples. Using Hadoop/HBase for the distributed data warehouse, Energy-CRADLE does not have a predefined data table schema, which enables ingestion of data in diverse and changing formats. For easy data ingestion and data retrieval, Energy-CRADLE utilizes Hadoop streaming to enable Python MapReduce and provides a graphical user interface, i.e., py-CRADLE. By developing the Hadoop distributed computing platform and the HBase NoSQL database schema for solar energy, Energy-CRADLE exemplifies an integrated, scalable, secure, and user-friendly data informatics and analytics system for PV researchers. Furthermore, an example of Energy-CRADLE enabled scalable, data-driven, analytics is presented, where machine learning is used for anomaly detection across 2.2 million real-world current-voltage (I–V) curves of PV modules in three distinct Koppen–Geiger climatic zones.

14 SOLAR ENERGY↗
DOE OSTI2016

On the Path to SunShot - The Role of Advancements in Solar Photovoltaic Efficiency, Reliability, and Costs

Although tremendous progress has been made in reducing the cost of PV systems, additional LCOE reductions of 40%–50% between 2015 and 2020 will be required to reach the SunShot Initiative’s targets (see Woodhouse et al. 2016). Understanding the tradeoffs between installed prices and other PV system characteristics—such as module efficiency, module degradation rate, and system lifetime—are vital. For example, with 29%-efficient modules and high reliability (a 50-year lifetime and a 0.2%/year module degradation rate), a residential PV system could achieve the SunShot LCOE goal with modules priced at almost $1.20/W. But change the lifetime to 10 years and the degradation rate to 2%/year, and the system would need those very high-efficiency modules at zero cost to achieve the same LCOE. Although these examples are extreme, they serve to illustrate the wide range of technological combinations that could help drive PV toward the LCOE goals. SunShot’s PV roadmaps illustrate specific potential pathways to the target cost reductions.

14 SOLAR ENERGY↗
DOE OSTI2022

Exploring Si Heterojunction Solar Cell Degradation: Bulk and Interface Processes Analyzed by Simulations and Experiments in Order to Develop Mitigation Strategies

The Si technology with the highest conversion efficiency is a-Si/c-Si heterojunction (HJ) PV. Its market penetration, however, is slowed by reports that fielded HJ modules degraded at twice the rate of regular c-Si modules. Our very recent work confirmed this degradation and attributed it to enhanced recombination at the a-Si/c-Si interface, caused by the slow, order-of-magnitude increase of the defect density. We propose to comprehensively explore degradation mechanisms in Si HJ cells by combining simulations and experiments. Theoretically, we will: (1) simulate structure of a-Si and a-Si/c-Si interfaces, identify defects; (2) determine statistics of energy barriers that control defect formation; (3) compute growth of defect density from the barrier distribution, and the resulting degradation of Voc. Experimentally, we will: (1) create a series of HJ-cell-representative stacks with varying layer thicknesses and deposition conditions by using PECVD tools; (2) use temperature and injection-dependent lifetime spectroscopy to determine effective lifetimes; (3) deconvolve the data to separate bulk and interface effects, and the effects of charge density and interface defects to analyze long time degradation. The goal is to identify material and device degradation mechanisms, to develop mitigation strategies for improved stability, such as the introduction of capping layers and hydrogen diffusion control.

14 SOLAR ENERGY↗
DOE OSTI2013

Innovative Application of Maintenance-Free Phase-Change Thermal Energy Storage for Dish-Engine Solar Power Generation

This final report summarizes the final results of the Phase II Innovative Application of Maintenance-Free Phase-Change Thermal Energy Storage for Dish-Engine Solar Power Generation project being performed by Infinia Corporation for the U.S. Department of Energy under contract DE-FC36-08GO18157 during the project period of September 1, 2009 - August 30, 2012. The primary objective of this project is to demonstrate the practicality of integrating thermal energy storage (TES) modules, using a suitable thermal salt phase-change material (PCM) as its medium, with a dish/Stirling engine; enabling the system to operate during cloud transients and to provide dispatchable power for 4 to 6 hours after sunset. A laboratory prototype designed to provide 3 kW-h of net electrical output was constructed and tested at Infinia's Ogden Headquarters. In the course of the testing, it was determined that the system's heat pipe network - used to transfer incoming heat from the solar receiver to both the Stirling generator heater head and to the phase change salt - did not perform to expectations. The heat pipes had limited capacity to deliver sufficient heat energy to the generator and salt mass while in a charging mode, which was highly dependent on the orientation of the device (vertical versus horizontal). In addition, the TES system was only able to extract about 30 to 40% of the expected amount of energy from the phase change salt once it was fully molten. However, the use of heat pipes to transfer heat energy to and from a thermal energy storage medium is a key technical innovation, and the project team feels that the limitations of the current device could be greatly improved with further development. A detailed study of manufacturing costs using the prototype TES module as a basis indicates that meeting DOE LCOE goals with this hardware requires significant efforts. Improvement can be made by implementing aggressive cost-down initiatives in design and materials, improving system performance by boosting efficiencies, and by refining cost estimates with vendor quotes in lieu of mass-based approaches. Although the prototype did not fully demonstrate performance and realize projected cost targets, the project team believes that these challenges can be overcome. The test data showed that the performance can be significantly improved by refining the heat pipe designs. However, the project objective for phase 3 is to design and test on sun the field ready systems, the project team feels that is necessary to further refine the prototype heat pipe design in the current prototype TES system before move on to field test units, Phase 3 continuation will not be pursued.

14 SOLAR ENERGY↗
DOE OSTI2021

Nanomechanical and Fluorescence Characterizations of Weathered PV Module Encapsulation

Nanoindentation and fluorescence spectroscopy provide spatially resolved mechanical and chemical characterization for degradation of poly (ethylene-co-vinyl acetate) (EVA) encapsulants aged under accelerated weathering and in field deployed photovoltaic (PV) modules. For the accelerated weathering tests, two different EVA formulations in the glass/EVA/glass-laminated coupons were exposed to ultraviolet (UV) light for 180 days at three different temperatures (40, 60, and 80 °C) and UV intensities (0.4, 2.2, and 2.9 W/m2/nm at 340 nm). The fluorescence spectra and moduli were uniform through the cross section of both EVA formulations at the lowest temperature and UV intensity; however, under the highest temperature and UV intensity, the UV irradiated sides showed lower moduli and higher fluorescence compared to the opposite sides. For EVA obtained from PV modules deployed 27 years in Sacramento, CA, USA, changes in fluorescence intensity across the thickness were relatively greater than changes in modulus. On the other hand, for EVA obtained from the same type of module stored in the shed for 27 years, no fluorescence was observed, and a uniform modulus was seen through the EVA layer, but with substantially higher values than those obtained from the field-deployed modules. The different extent of changes between laboratory and field exposures suggests the importance of considering effects of temperature and UV intensity for designing a reliable accelerated testing. This study uniquely demonstrates the capability of microscale characterization using nanoindentation and fluorescence microscopy to monitor mechanical and chemical degradation of EVA encapsulants in PV modules.

14 SOLAR ENERGY↗
DOE OSTI2018

Using Module Leakage Current Modeling to Understand Corrosion Chemistry

When fielded, modules are exposed to high voltages in the presence of moisture and/or elevated temperature this allows significant leakage currents to flow between the cell and ground. When current changes from an electronic to an ionic form, electrochemical reactions are promoted creating the potential for a wide variety of degradation reactions. This work investigates the nature of this current flow to gain a better understanding of the effect. At the cell surface, current preferentially flows to the metallization and under negative bias will split water to form OH - ions. It is found that transient effects occur in the leakage current as a result of some capacitive and electrochemical effects. This work seeks to provide important insight into the nature of the charge transfer species and the factors that most strongly affect leakage rates to provide better correlation to module performance.

14 SOLAR ENERGY↗
DOE OSTI2020

Technoeconomic Analysis of Photovoltaics Module Manufacturing with Thin Silicon Wafers

Reducing silicon usage by adopting thinner wafers can significantly reduce capital expenditure (capex) and cost, and thus accelerate the growth of manufacturing capacity and deployment. In this work, we evaluated potential benefits of thin Si wafers for current and future PV modules. We apply a technoeconomic framework that couples bottom-up cost model, and a cash-flow growth model to analyze PV modules with thin wafers. First, we show that, comparing the current PERC with 160 um thick wafers to the high-efficiency concept with 50 um thin wafers, the capex is reduced from 0.39 to 0.2 $/(W/year) while the cost is from 0.32 to 0.2 $/W. Second, the potential of accelerated deployment is analyzed for the highefficiency thin wafer concept. We found the significant advantages of higher growth rate (~20% relative) and higher deployment plateau (~3 times) than the current PERC modules. modules with thin wafers. First, we show that, comparing the current PERC with 160 um thick wafers to the high-efficiency concept with 50 um thin wafers, the capex is reduced from 0.39 to 0.2 $/(W/year) while the cost is from 0.32 to 0.2 $/W. Second, the potential of accelerated deployment is analyzed for the highefficiency thin wafer concept. We found the significant advantages of higher growth rate (~20% relative) and higher deployment plateau (~3 times) than the current PERC modules.

14 SOLAR ENERGY↗
DOE OSTI2019

Suggested Modifications for Bifacial Capacity Testing: Preprint

Capacity tests such as those described in ASTM 2848 and IEC 61724-2 are widely used during the contracting and acceptance testing of PV systems. With the increasing deployment of bifacial PV modules, there is a need to develop a standardized approach to capacity test these systems. Although variability and bias error was inherently higher for the measured capacity of bifacial systems, it could be reduced to a level consistent with the monofacial reference system by appropriate incorporation of rear irradiance- either measured or modeled. Three field installations provided bifacial system capacity that was measured with a mean bias error and standard deviation within 1% over the 2-10 month observation period. Capacity test accuracy could be improved further by utilizing measured back-of-module temperature and the IEC 61724-2 test method.

14 SOLAR ENERGY↗
DOE OSTI2018

Photovoltaic Recycling Processes

Solar photovoltaic (PV) installations must be properly dismantled and any waste treated and disposed of at the end of project life. However, because most of the world's nearly 400 GW of PV systems have been built in the past decade - each expected to operate for between 20 and 30 years-current PV module waste volumes do not yet justify widespread operation of PV recycling facilities. In anticipation of increasing demand however, several recycling companies are evaluating the PV waste market to assess waste-volume growth. Others are pursuing research- and pilot-stage PV module recycling activities. The latter are mostly commercial laminated glass and metal recyclers that process batches of PV modules on a periodic basis. This report describes a recent survey-based evaluation of existing commercial and pilot-scale recycling processes in Europe, and associated life cycle inventory data.

14 SOLAR ENERGY↗