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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 163 records · Page 9
All sourcesNASA NTRSDOE OSTI
DOE OSTI2020

Rapid Open-Air Fabrication of Perovskite Solar Modules

We report on the open-air fabrication of perovskite solar modules with key advances including scalable large-area spray deposition, new monolithic integration scribing techniques, advanced photoluminescence characterization, and reproducible high-throughput manufacturability. Perovskite deposition with linear speeds of 12 m/min without a post-anneal are demonstrated with improved device performance, luminescent yield and >10X carrier lifetimes. Manufacturability using monolithic integration of series-connected modules is accomplished with a new indirect fiber laser ablation scribing method. A stable cell and module power output of 18.0% and 15.5%, respectively, was achieved with a subcell V oc > 1.06V. A comprehensive supporting technoeconomic analysis details the entire in-line manufacturing process from the glass substrate to the junction box of the encapsulated module. Here, the module manufacturing cost, balance of system costs and levelized cost of energy for a range of module efficiencies and lifetimes provides insights for the necessary tool speeds, efficiencies, and lifetimes for utility-scale energy generation.

14 SOLAR ENERGY↗
DOE OSTI2025

In‐Scribe Silane Bonding for Mechanical Reinforcement of Perovskite Photovoltaic Modules

Despite the extraordinary rise in power conversion efficiency over the last decade, metal halide perovskite (MHP) photovoltaics remain more mechanically fragile than other PV technologies. In this work, the scribe area, created by the monolithic interconnection of thin-film solar cells, is used to extrinsically reinforce the mechanical robustness of packaged MHP solar modules. In contrast to the epoxy-based chemistries often leveraged in the MHP literature, silane-grafted polyolefin encapsulants are designed to form strong covalent bonds to oxide surfaces, specifically to glass and the transparent conductive oxide at the base of the scribe line. Pseudo-modules encapsulated with silane-grafted polyolefin are measured with more than an order-of-magnitude enhancement infracture energy from 0.27 ± 0.01 J·m −2 (no scribes) to 5.97 ± 0.42 J·m −2 (scribes perpendicular to delamination directioncovering ≈2.2% of the module area). The silane-grafted polyolefin retains strong adhesion even after undergoing an accelerated IEC 61215 thermal cycling test consisting of 250 cycles. We find that the in-scribe bonding allows perovskite modules to have adhesion strength comparable to commercial c-Si and CdTe technologies with only 5% reduction in the active module area. This manufacturing-compatible approach offers a practical solution to address the mechanical integrity challenges in MHP solar modules, regardless of cell architecture.

14 SOLAR ENERGY↗
DOE OSTI2021

Rapid Open-Air Processing of Low-Cost Perovskite Solar Modules

We report an industrially relevant approach to both scalable and fast open-air perovskite photovoltaic (PV) module production. This work resolves some of the most formidable barriers to module-level scaling that the perovskite community has been facing. Key advances include scalable large-area spray deposition, new monolithic integration scribing techniques, advanced photoluminescence characterization, and reproducible high-throughput manufacturability. Our rapid spray processing techniques enabled the highest perovskite PV efficiency produced in open-air. Innovations in scribing techniques enabled the first single-source laser process to achieve perovskite module monolithic integration and technoeconomic analysis led to a comprehensive cost model for perovskite module manufacturing. We report significant progress in reducing perovskite manufacturing costs necessary to potentially compete with incumbent Si-based PV for utility-scale power generation.

cost modeling↗
DOE OSTI2017

Cooperative effort between Consorcio European Spallation Source--Bilbao and Oak Ridge National Laboratory spallation neutron source for manufacturing and testing of the JEMA-designed modulator system

The JEMA modulator was originally developed for the European Spallation Source (ESS) when Spain was under consideration as a location for the ESS facility. Discussions ensued and the Spallation Neutron Source Research Accelerator Division agreed to form a collaboration with ESS-Bilbao (ESS-B) consortium to provide services for specifying the requirements for a version of the modulator capable of operating twelve 550 kW klystrons, monitoring the technical progress on the contract with JEMA, installing and commissioning the modulator at SNS, and performing a 30 day full power test. This work was recently completed, and this report discusses those activities with primary emphasis on the installation and testing activities.

43 PARTICLE ACCELERATORS↗
DOE OSTI2024

Optimal Design Approaches for Cost-Effective Manufacturing & Deployment of Chemical Process Families with Economies of Numbers

This work builds on our optimization formulation for process family design and extends it to explicitly include the benefits of economies of numbers. Economies of numbers (sometimes referred to as economies of learning) is a well-documented cost saving phenomenon. It characterizes the manufacturing cost savings due to standardization; in particular, it is capturing the correlation between cost reduction and the number of times a particular product has been manufactured. Following an approach similar to that in Gazzaneo et al. (2022), we develop a costing expression that captures material costs and manufacturing costs as a function of the number of unit modules produced. If the platform has a small number of unit module designs, we will be manufacturing a large number of each of these designs and gaining increased benefits from economies of numbers. However, increasing the number of unit module designs in the platform gives each process variant more choices to consider (at the cost of reducing economies of numbers). The optimization formulation in Stinchfield et al. (2023) pre-specified the number of unit module designs to be included in the platform. Here, by including the economies of numbers explicitly, we allow the mathematical programming formulation to determine the optimal number of unit module designs to include in the platform. We demonstrate this approach on multiple case studies, including MEA-based carbon capture and water desalination.

Stinchfield, Georgia↗
DOE OSTI2016

Status of Electronics Upgrades to the LANL Green is Clean Phoswich Detector Systems - 16419

Los Alamos National Laboratory radiological facilities produce low-density room trash that, in many cases, is not contaminated with radioactivity. It has been estimated that 50 to 90% of low-density room trash is free of radioactive contamination and eligible for inclusion in LANL's Green is Clean (GIC) program. The GIC program is a verification program for non-regulated waste from radiation controlled areas that has been actively segregated as nonradioactive through the use of the waste generator's acceptable knowledge. The GIC program has employed two large area Phoswich gamma ray detector systems (HERCULES and ZEUS) to assay and verify that GIC candidate waste meets free release disposal requirements. The large area (127 cm{sup 2}) Phoswich detectors consist of a thin NaI front crystal (3 mm thick) that is optically coupled to a thick CsI back crystal (50 mm thick). The crystals are set in an oxygen-free high-conductivity copper housing with a very thin (0.025 mm) aluminum entrance window. The scintillation properties of the two crystals are different enough to allow the system's electronic components to identify the origin of any pulse. The original systems utilize Nuclear Instrumentation Module (NIM) electronics to process the detector signals. These electronic modules provide the buffering, amplification, and pulse shape analyzer needed for the proper presentation of signals to the custom Phosmux router module. The router module separates the sodium iodide and cesium iodide signals by their rise times and transfers this information into the computer-mounted multichannel analyzer, a Canberra Model S-100 system. While these NIM Bin counting electronics configurations have been effective for approximately 20 years of operation, they are bulky requiring numerous modules per detector and the important Phosmux module is no longer manufactured by LANL. Modern advancement of commercial counting electronics now offer more compact options for equivalent detector signal processing. A pulse shape discriminator module, the DGF Pixie-4, made by XIA LLC, has been identified that can replace the majority of the original NIM bin electronics in a much more compact chassis - one Pixie-4 replaces four NIM amplifiers and four NIM PSAs and fits in a small National Instruments{sup TM} chassis. Thus, LANL has initiated a system upgrade project to replace the historic NIM electronics with the XIA Pixie4 and associated configuration software. The hardware for one Phoswich systems has been procured for the project and the configuration software, customized for the LANL Phoswich detector application, has been written by the manufacturer. Initial setup and optimization of the Pixie-4 configuration has been performed. Qualitative and quantitative baseline comparisons to the NIM electronics has been performed. Good agreement of key low energy gamma lines between the systems has allowed 'Proof of Concept' to be concluded. Further optimization and performance evaluations are in progress. Modifications to the LabVIEW{sup TM} based operating software (originally written by VI Control Systems Ltd.) are being performed by a LANL LabVIEW{sup TM} programmer to accommodate the electronics upgrade. A new LabVIEW{sup TM} interface to control the Pixie-4 has already been developed. Final optimization and testing, formal software QA, and revisions to operating procedures are in progress to achieve completion of the GIC system upgrade project. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2018

Self-Reference Procedure to Reduce Uncertainty in Module Calibration

This paper presents a composite measurement approach that capitalizes on complimentary strengths of 3 different test beds to significantly reduce uncertainty in I-V parameters for secondary module calibration. This approach addresses PV manufacturers' need for reduced uncertainty in the calibration modules that provide the basis for their module power ratings. This new method enables NREL to reduce uncertainty for secondary module calibration in commercial c-Si modules from +/-3.2% to +/-0.7% for I SC and from +/-3.3% to +/-1.1% for P MAX . This new module self-reference, or MSR procedure is based on the sensitivity of module voltage to temperature plus the uniformity of outdoor sunlight. By calibrating module V OC in thermal equilibrium on a flash simulator we provide an accurate gauge of junction temperature for subsequent measurements. By calibrating I SC outdoors in natural sunlight we enable the module to serve as its own reference device in setting the intensity of a continuous simulator, effectively eliminating the impact of spatial non-uniformity and spectral mismatch on the I-V measurement. These procedures significantly reduce measurement errors due to temperature uncertainty, spatial non-uniformity, and spectral mismatch.

14 SOLAR ENERGY↗
DOE OSTI2020

Cost Efficient and Highly Weather-Resistant Solar Panel Backsheet Produced through Continuous Co-Extrusion Processing

The efficient generation and delivery of ‘clean energy” through photovoltaic (PV) technology relies heavily on the cost, performance and reliability of solar panels, along with the individual components used in assembly of those panels. In order to continue towards the Department of Energy’s (DOE) goals of driving costs down, the lifetime of high-output power generation equipment (i.e. solar modules) must be extended to reduce costs associated with power output degradation and replacement of failed or degraded panels. One of the major sources of module failures in the past 30 years has been the failure of the solar panel backsheet. Failure of this component causes severe output losses due to oxidation and yellowing of the module while creating safety concerns as the major electrical insulation of the module is compromised. Tomark-Worthen LLC was formed in 2012 with the goal of designing and manufacturing novel PV backsheets and encapsulants that would be produced in the United States of America and exceed expectations of domestic and international module producers. These backsheets would improve upon known backsheet design failures (i.e. Isovoltaic’s AAA backsheet) and create domestic manufacturing jobs in the PV sector. This goal became a reality with a first-generation product in 2018 and now, with the support of the DOE, Tomark-Worthen has launched a second-generation product known as PhotoMark® Reflections™ 205-3 and 360-3. This 2+ year effort began in late 2017 with a screening of potential polymeric materials and backsheet structural designs. Performance evaluations of each material provided the necessary data needed to select the proper material combinations and move forward into the design of the manufacturing process. These decisions were made by teaming with a local university, well-respected government laboratories, and private research organizations who provided the tools necessary to predict long-term performance of these materials in much shorter periods of time. Once the go/no-go criteria were met at the mid-point of the project, the effort transitioned to predicting 30+ year performance, achieving certifications, and improving manufacturing efficiencies designed to lower costs in order to be competitive in a cost-driven market. Major project accomplishments include recognition of the new backsheet by Underwriters Laboratories (UL) and international certification for 1000V and 1500V modules by TUV Sud. Both 1000V and 1500V products have been proven on several module manufacturing lines and initial customer orders have been received by both domestic and international module producers. Accelerated exposure testing has shown that the performance of this backsheet exceeds the prior polyamide-based backsheet known to fail in the field. Cost-models and initial customer orders have shown the ability to produce this backsheet at a cost acceptable to many domestic manufacturers, while International costs for standard backsheet remains extremely low. Tomark-Worthen remains one of the only U.S. companies manufacturing backsheet domestically and this has drawn interest from many domestic module manufacturers looking to improve their material supply logistics by avoiding long lead times and custom’s headaches while avoiding current tariffs on Chinese-made components. Along with the launch of a new PV backsheet, this project has provided a critical deliverable to the PV R&D community. This deliverable is the knowledge that not all polyamide-containing backsheets are doomed to failure as the earlier versions did. There has been a fear amongst the PV community to consider these materials due to the failure of one design. This effort has brought a new level of interest to the scientific community as it has been shown that polyamides can be used successfully in a well-designed backsheet. As we move forward from this project, we are excited to see how backsheet technology and manufacturing in the U.S. will continue to progress and grow.

14 SOLAR ENERGY↗
DOE OSTI2015

TU-F-CAMPUS-I-04: A Novel Phantom to Evaluate Longitudinal and Angular Automatic Tube Current Modulation (ATCM) in CT

Purpose: To manufacture a phantom specifically designed for the purpose of evaluating the performance of the longitudinal and angular automatic tube current modulation (ATCM) on modern CT scanners. Methods: In order to evaluate angular ATCM, the phantom has an elliptical cross section (aspect ratio 3:2). To evaluate longitudinal ATCM, the phantom consists of 3 sections, with different major axes (25 cm, 30 cm and 35 cm). Each section is 15 cm long in the longitudinal direction. Between each section is a smooth transition. The phantom was milled from a solid block of PMMA. ATCM performance is evaluated by 1) analyzing the applied tube current for each slice of the phantom and 2) analyzing the distribution of image noise (σ) along the scan direction at different positions in the phantom. A demonstration of the ATCM performance evaluation is given by investigating the effects of miscentering during a CT scan. Results: The developed phantom has proven useful for evaluating both the longitudinal and angular ATCM on modern CT scanners (spiral collimations ≥ 4 cm). Further benefits are the smooth transitions between the sections that prevent abnormal responses in the ATCM and the invariant sections that provide a means for investigating the stability of image noise. The homogeneity of the phantom makes image noise at different positions along the scan direction easy to quantify, which is crucial to understand how well the applied ATCM can produce a desired image quality. Conclusion: It is important to understand how the ATCM functions on CT scanners as it can directly affect dose and image quality. The phantom that has been developed is a most valuable tool to understand how different variables during a scan can affect the outcome of the longitudinal and angular ATCM.

60 APPLIED LIFE SCIENCES↗
DOE OSTI2022

Automated defect identification in electroluminescence images of solar modules

Solar photovoltaic (PV) modules are susceptible to manufacturing defects, mishandling problems or extreme weather events that can limit energy production or cause early device failure. Trained professionals use electroluminescence (EL) images to identify defects in modules, however, field surveys or inline image acquisition can generate millions of EL images, which are infeasible to analyze by rote inspection. Here, we develop a rapid automatic computer vision pipeline (~0.5 seconds/module) to analyze EL images and identify defects including cracks, intra-cell defects, oxygen-induced defects, and solder disconnections. Defect identification is achieved with a machine learning model (Random Forest, ResNet models and YOLO) trained on 762 manually-labeled EL images of PV modules. We compare model performance on an imbalanced real-world validation set containing 134 EL images and determine that ResNet18 and YOLO are the optimal models; we next evaluated these models on a dedicated testing set (129 module images) with resulting macro F1 scores of 0.83 (ResNet18) and 0.78 (YOLO). Using a field EL survey of a PV power plant damaged in a vegetation fire, we analyze 18,954 EL images (2.4 million cells) and inspect the spatial distribution of defects on the solar modules. The results find increased frequency of ‘crack’, ‘solder’ and ‘intra-cell’ defects on the edges of the solar module closest to the ground after fire. We also find an abnormal increase of striation rings on cells which were assumed to be caused mainly in fabrication process. Our methods are published as open-source software. It can also be used to identify other kinds of defects or process different types of solar cells with minor modification on models by transfer learning.

14 SOLAR ENERGY↗
DOE OSTI2022

Developing Novel Performance Measures for Traffic Congestion Management and Operational Planning Based on Connected Vehicle Data

In this study, the authors present their efforts in exploring a new type of traffic data, referred to as internet-connected vehicle (ICV) data, for traffic congestion management and operational planning. Most currently manufactured vehicles contain onboard GPS and cellular modules, and they constantly connect to automobile manufacturers' clouds via cellular networks and upload their status. Some automobile manufacturers have recently redistributed the nonpersonal part of such data, such as geolocation, to third-party organizations for innovative applications. Compared with the traditional vehicle GPS data, the ICV data contain high-resolution GPS waypoints accompanied with the vehicles' abnormal moving events (e.g., hard braking). The ICV data also have huge potential in congestion management and operational planning. They explore to identify and analyze traffic congestion on both freeways and arterials using the ICV data. The ICV data adopted for this research are redistributed by Wejo Data Service, representing 10%-15% of all moving vehicles in the Dallas-Fort Worth (DFW) area in Texas. Through one case study for a freeway segment and one for an arterial segment, new traffic performance metrics based on the characteristics of ICV data have been presented. The highlights of these efforts are as follows: (I) queue length and propagation at freeway bottlenecks can be directly measured based on where and when most internet-connected vehicles slow down and join the queue; (II) an internet-connected vehicle's actual delay time on arterials can be directly measured according to its slow movement percentage, without assuming the nondelay travel speed; and (III) the ICV data set are also combined with the high-resolution traffic signal events to generate a ground-truth time-space diagram (TSD) on arterials - a common visualization of arterial signal performance for transportation planning and operations.

33 ADVANCED PROPULSION SYSTEMS↗
DOE OSTI2021

Moose Application Library For Advanced Manufacturing Utilities

MALAMUTE combines MOOSE module functionality with realistic materials and geometries for arbitrary-Eulerian-Lagrangian (ALE) and level-set based laser melting and welding applications and electric-field assisted sintering (EFAS) applications.

Lindsay, AlexanderD.↗
DOE OSTI2018

Method and device for a high temperature vacuum-safe solder stop utilizing laser processing of solderable surfaces for an electronic module assembly

A process for manufacturing an electronic component having attaches includes providing a first component having a first attach, forming trenches on a portion of the first attach with a laser to form a solder stop, and providing a second component comprising a second attach. The process further includes providing solder between the first attach and the second attach to form a connection between the first component and the second component, where the trenches contain the solder to a usable area. A device produced by the process is disclosed as well.

Stabach, Jennifer↗
DOE OSTI2021

Method and device for a high temperature vacuum-safe solder resist utilizing laser ablation of solderable surfaces for an electronic module assembly

A process for manufacturing an electronic component having attaches includes providing a first component having a first attach, forming trenches on a portion of the first attach with a laser to form a solder stop, and providing a second component comprising a second attach. The process further includes providing solder between the first attach and the second attach to form a connection between the first component and the second component, where the trenches contain the solder to a usable area. A device produced by the process is disclosed as well.

Stabach, Jennifer↗
DOE OSTI2019

Novel CO 2 -Selective Membranes for CO 2 Capture from <1% CO 2 Sources

The objective of this project is to develop a cost-effective design and fabrication process for a new membrane and its membrane modules that capture CO 2 from <1% CO 2 concentration sources. Synthesis of novel CO 2 -selective membranes using a cost-effective nanoporous polyethersulfone (PES) polymer support and coating a top layer of thin, highly selective, yet permeable amine-containing polymer membrane has been performed. Pilot-size membranes (about 14 inches in width, the change was made from lab-size membranes with about 6 inches by 6 inches to gain more progress) have been used to fabricate at least 3 pilot-size membrane modules (each about 14-inch long) for lab testing with the simulated gas mixture. The pilot membrane modules have been in commercial configurations, i.e., plate-and-frame (PF) and spiral-wound (SW), for a minimal pressure drop (<0.103 bar/meter (1.5 psi (pounds per square inch)/meter)). Both PF and SW modules fabricated gave similar performance and acceptable pressure drop results. We down-selected to the SW module for ease of manufacture.

2-stage process↗
DOE OSTI2023

CdTe-based thin film photovoltaics: Recent advances, current challenges and future prospects

Cadmium telluride (CdTe)-based cells have emerged as the leading commercialized thin film photovoltaic technology and has intrinsically better temperature coefficients, energy yield, and degradation rates than Si technologies. More than 30 GW peak (GWp) of CdTe-based modules are installed worldwide, multiple companies are in production, modules are shipping at up to 18.6% efficiency, and lab cell efficiency is above 22%. We review developments in the science and technology that have occurred over approximately the past decade. These achievements were enabled by manufacturing innovations and scaling module production, as well as maximizing photocurrent through window layer optimization and alloyed CdSe x Te 1-x (CST) absorbers. Improved chlorine passivation processes, film microstructure, and serendipitous Se defect passivation significantly increased minority carrier lifetime. Efficiencies >22% have been realized for both Cu and As doped CST-based cells. The path to further efficiency gains hinges primarily on increasing open circuit voltage (V oc ) and fill factor (FF) through innovations in materials, fabrication methods, and device stacks. Replacing the longstanding Cu doping with As doping is resulting in better module stability and is being translated to large-scale production. To realize 25% efficiency and >1 V V oc , research and development is needed to increase the minority carrier lifetime beyond 100 ns, reduce grain boundary and interface recombination, and tailor band diagrams at the front and back interfaces. Many of these goals have been realized separately however combining them together using scalable manufacturing approaches has been elusive to date. We review these achievements and outstanding opportunities for this remarkable photovoltaic technology.

14 SOLAR ENERGY↗
DOE OSTI2023

Susceptibility to polarization type potential induced degradation in commercial bifacial p-PERC PV modules

Potential induced degradation (PID) is a reliability issue affecting photovoltaic (PV) modules, mainly when PV strings operate under high voltages in hot/humid conditions. Polarization-type PID (PID-p) has been known to decrease module performance quickly. PID-p can be reduced or recovered under the light in some cases, but this effect, as expected, would be less pronounced on the rear side of bifacial PV modules receiving lower irradiance. As bifacial PV modules are projected to dominate the PV market within the next 10 years, it is crucial to understand the PID-p issue in bifacial modules better. In this study, we performed indoor PID testing to induce PID-p on 14 commercial bifacial p-PERC modules with three different module constructions from three manufacturers. Here, four rounds (+ve and –ve polarities for front and rear sides) of PID testing are done at 25°C, 54% relative humidity (RH) for 168 h using the aluminum foil method. Each module side (front cell side and back cell side) is tested individually under both negative and positive voltage bias. The results show that the highest degradation of 32% in maximum power (Pmax) at standard test conditions (1000 W/m 2 ) and 51% at low irradiance (200 W/m 2 ) has been observed in some cases. Recovery under sunlight is also done, and outcomes show a near-complete recovery in Pmax. This study presents an extensive experimental methodology and a detailed analysis to systematically and simultaneously/sequentially evaluate multiple construction types of bifacial modules to the PID-p susceptibility and recovery.

14 SOLAR ENERGY↗