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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 OSTI2025

Open data sets for assessing photovoltaic system reliability

Photovoltaic (PV) systems have become a cornerstone of renewable energy strategies, particularly due to the significant reduction in solar power costs over the past decade. However, the long-term reliability of PV installations presents a persistent challenge, requiring the development of advanced monitoring and predictive maintenance strategies. A wide range of data types is used to evaluate the health of PV systems, including environmental conditions, electrical performance, and inspection imagery. These data enable methodologies such as machine learning (ML) models for lifetime prediction and computer vision techniques for defect detection. However, the acquisition of high-quality and comprehensive data is difficult, particularly in terms of long-term consistency and data variety. Publicly available data sets serve as valuable resources for addressing these challenges, but they often suffer from fragmentation and are difficult to access. This paper presents a comprehensive review of existing open-source data sets related to PV degradation, analyzing their features, functionalities, and potential applications. We categorize these data sets based on the specific aspects of PV system information they cover, such as environmental conditions, operational monitoring, image inspection and module materials, and propose relevant tools and ML models for processing them. In addition, we propose practices for future data collection and usage, while also discussing potential directions in data-driven research. Our aim is to enhance data utilization and publication among researchers and industry professionals, promoting a deeper understanding of the role of data in enhancing the performance and durability of PV systems.

14 SOLAR ENERGY↗
DOE OSTI2021

PV Evolution in the Light of Circular Economy

As photovoltaic (PV) deployments increase, the increasing material volume presents challenges throughout the supply chain and eventual end-of-life waste management. Quantifying the value of lifetime, reliability, repair, reuse, recycling, and other options to increase circularity can help identify and prioritize research and technical solutions required to integrate PV into the circular economy. In this work, we capture the evolution of PV module technology, such as improved reliability and increasing market share of glass/glass modules. We discuss material circularity, lifetime and reliability, and energy return on investment as quantitative metrics to define and evaluate circularity and sustainability.

bifacial↗
DOE OSTI2019

Stress and Fracture of Crystalline Silicon Cells in Solar Photovoltaic Modules – A Synchrotron X-ray Microdiffraction based Investigation

Fracture of crystalline silicon (c-Si) solar cells in photovoltaic modules is a big concern to the photovoltaics (PV) industry. Cell cracks cause performance degradation and warranty issues to the manufacturers. The roots of cell fractures lie in the manufacturing and integration process of the cells and modules as they go through a series of elevated temperature and pressure processes, involving bonding of dissimilar materials, causing residual stresses. Evaluation of the exact physical mechanisms leading to these thermomechanical stresses is highly essential to quantify them and optimize the PV modules to address them. Here we present a novel synchrotron X-ray microdiffraction based techniques to characterize the stress and fracture in the crystalline silicon PV modules. We show the detailed stress state after soldering and lamination process, using the synchrotron X-ray microdiffraction experiments. We also calculate the maximum tolerable microcrack size in the c-Si cells to sustain the residual stress after lamination. We further demonstrate the effect of these residual stresses on the cell fractures using the widely accepted fracture (4-point bending) tests. These test results show that the soldering and lamination induced localized residual stresses indeed reduce the load-carrying capacity of the c-Si cells.

14 SOLAR ENERGY↗
DOE OSTI2024

Encapsulation Materials Tailored to Perovskite Photovoltaics

The work combines NREL as the world leader in perovskite and polymeric materials, and teams them up with The Dow Chemical Company, the world leader in commercial production of PV encapsulation materials. The team will design and evaluate encapsulation materials that are tailored to perovskite photovoltaics. Demonstration of polyolefin-based encapsulants for perovskite PV will be impactful for a number of reasons: 1) There is no clear-cut choice for encapsulation for perovskite PV to date. 2) There is high synthetic control of the material properties for future perovskite module designs. 3) Among the candidate materials, they have the highest barrier properties, 4) Polyolefins are the most prevalent (>20 million metric tons consumed in the US alone) and inexpensive (<1.5 $USD/kg) polymers used worldwide. 5) They are recyclable and may play a role in future of circular PV materials. 6) They are manufactured domestically. The work also highlights careful design of perovskite transport layer materials for surviving vacuum encapsulation.

14 SOLAR ENERGY↗
DOE OSTI2023

Open‐source photovoltaic model pipeline validation against well‐characterized system data

Abstract All freely available plane‐of‐array (POA) transposition models and photovoltaic (PV) temperature and performance models in pvlib‐python and pvpltools‐python were examined against multiyear field data from Albuquerque, New Mexico. The data include different PV systems composed of crystalline silicon modules that vary in cell type, module construction, and materials. These systems have been characterized via IEC 61853‐1 and 61853‐2 testing, and the input data for each model were sourced from these system‐specific test results, rather than considering any generic input data (e.g., manufacturer's specification [spec] sheets or generic Panneau Solaire [PAN] files). Six POA transposition models, 7 temperature models, and 12 performance models are included in this comparative analysis. These freely available models were proven effective across many different types of technologies. The POA transposition models exhibited average normalized mean bias errors (NMBEs) within ±3%. Most PV temperature models underestimated temperature exhibiting mean and median residuals ranging from −6.5°C to 2.7°C; all temperature models saw a reduction in root mean square error when using transient assumptions over steady state. The performance models demonstrated similar behavior with a first and third interquartile NMBEs within ±4.2% and an overall average NMBE within ±2.3%. Although differences among models were observed at different times of the day/year, this study shows that the availability of system‐specific input data is more important than model selection. For example, using spec sheet or generic PAN file data with a complex PV performance model does not guarantee a better accuracy than a simpler PV performance model that uses system‐specific data.

14 SOLAR ENERGY↗
DOE OSTI2017

Encapsulant Adhesion to Surface Metallization on Photovoltaic Cells

Delamination of encapsulant materials from PV cell surfaces often appears to originate at regions with metallization. Using a fracture mechanics based metrology, the adhesion of ethylene vinyl acetate (EVA) encapsulant to screen-printed silver metallization was evaluated. At room temperature, the fracture energy Gc [J/m2] of the EVA/silver interface (952 J/m2) was ~70% lower than that of the EVA/antireflective (AR) coating (>2900 J/m2) and ~60% lower than that of the EVA to the surface of cell (2265 J/m2). After only 300 h of damp heat aging, the adhesion energy of the silver interface dropped to and plateaued at ~50-60 J/m2 while that of the EVA/AR coating and EVA/cell remained mostly unchanged. Elemental surface analysis showed that the EVA separates from the silver in a purely adhesive manner, indicating that bonds at the interface were likely displaced in the presence of humidity and chemical byproducts at elevated temperature, which in part accounts for the propensity of metalized surfaces to delaminate in the field.

14 SOLAR ENERGY↗
DOE OSTI2022

Test and Evaluation of Solar Foil Directly Mounted on the Ground (Final Report)

HyET Solar (HyET), established in 2012, is a small business developing a thin-film silicon solar photovoltaic (PV) product called "Power Foil" that can be mounted directly on the constructed earthen dykes. HyET's goals are for low-cost, efficient, generation of PV electricity at utility scale. HyET has requested assistance from the National Renewable Energy Laboratory (NREL) to evaluate the performance of the Power Foil product in several outdoor environments, with a particular focus on 1) heat effects on efficiency and 2) heat and UV effects on reliability and durability. NREL has been working on PV module testing at laboratory scale for more than 40 years, and has the equipment and facilities required to provide the PV material testing required.

14 SOLAR ENERGY↗
DOE OSTI2012

Standards for PV Modules and Components -- Recent Developments and Challenges: Preprint

International standards play an important role in the Photovoltaic industry. Since PV is such a global industry it is critical that PV products be measured and qualified the same way everywhere in the world. IEC TC82 has developed and published a number of module and component measurement and qualification standards. These are continually being updated to take advantage of new techniques and equipment as well as better understanding of test requirements. Standards presently being updated include the third edition of IEC 61215, Crystalline Silicon Qualification and the second edition of IEC 61730, PV Module Safety Requirements. New standards under development include qualification of junction boxes, connectors, PV cables, and module integrated electronics as well as for testing the packaging used during transport of modules. After many years of effort, a draft standard on Module Energy Rating should be circulated for review soon. New activities have been undertaken to develop standards for the materials within a module and to develop tests that evaluate modules for wear-out in the field (International PV Module QA Task Force). This paper will discuss these efforts and indicate how the audience can participate in development of international standards.

14 SOLAR ENERGY↗
DOE OSTI2019

Application of Electronics Packaging Fundamentals to Photovoltaic Interconnects and Packaging

The energy capacity of photovoltaic (PV) installations worldwide has increased significantly in the last decade, increasing the demand for rigorous investigation of the physical phenomena causing degradation and failures in PV modules. As PV reliability science develops, established methods and approaches from longer-standing industries can inform and expedite PV reliability advances. This work demonstrates how thermomechanical solder bond fatigue models derived for electronics packaging applications can be applied to both standard and emerging PV interconnect designs. This expertise cannot be directly translated to PV however, as target PV module lifetimes are significantly longer than most electronics and the modules must withstand the natural climate wherever they are deployed. Verification of analytical reliability models is then an additional challenge, due to model size, test time, and climate variability. Furthermore, unconventional materials, such as low-temperature solders, are now being integrated into PV designs, for which appropriate material models must be selected and material parameters derived. In this paper, the current state of PV interconnect research is explored, with an emphasis on the experimental and simulation approaches and models being used for this work. Recent results for standard module architectures as well as emerging interconnect schemes are discussed.

14 SOLAR ENERGY↗
DOE OSTI2019

Use of indentation to study the degradation of photovoltaic backsheets

The ability of electrical insulating materials within a module to act as insulators is a key safety requirement for photovoltaic (PV) technology. Presently, however, the durability of backsheets may not be readily assessed. For example, the mechanical tensile test continues to be developed, and its use has not been validated such that a technically based pass/fail criteria may be established. This study examines the use of simple indentation methods, including durometer hardness and instrumented indentation, as a means to quantitively assess the degradation of PV backsheets. Characteristics including: hardness, modulus, load/displacement profile, creep hold response, and residual impression are explored in an empirical study. Glass/encapsulant/backsheet mini-modules constructed using backsheets including: polyamide (PA), poly(ethylene terephthalate) (PET), polyvinyl fluoride (PVF) laminate ('TPE'), and polyvinylidene fluoride (PVDF) were examined. An M-type durometer as well as Berkovich and cube-corner tips were used in the indentation experiments. Additional characterizations were performed to interpret the indentation measurements including: surface roughness measurements using atomic force microscopy (AFM), a chemical integrity study using Fourier-transform infrared spectroscopy (FTIR), and phase-transition measurements using differential scanning calorimetry (DSC). The results are analyzed in the context of the combined accelerated stress test (C-AST) also explored in this study. Instrumented indentation (i.e., using a Berkovich tip) was able to distinguish between backsheets and quantify the effects of accelerated testing (including up to 60%, 25%, and 20% change in hardness, modulus, and creep displacement, respectively). The embrittlement of the backsheets was not readily assessable using cube-corner indentation. Cracking of the known-bad polyamide backsheet was observed from the C-AST, which was not observed to result from steady state UV weathering.

14 SOLAR ENERGY↗
DOE OSTI2011

Transfer Printed Microcells with Micro-Optic Concentrators for Low Cost, High Performance Photovoltaic Modules (Final Scientific and Technical Report)

This program of work established and validated a new form factor and fully scalable manufacturing processes for low cost, high performance photovoltaic modules. The programmatic highlights of the work include cost-effective assembly of modules fabricated from single crystalline semiconductor inks by high-throughput transfer printing of the micro-cells, advanced methods of systems level integration of sparse arrays, and design and fabrication of micro optical concentrator arrays that provide significant collection efficiencies of light and high performance of the system when integrated with the PV array module. The designs further provide efficient but fully passive heat management that simplifies fabrication while further enhancing operating capabilities of the modules. This collaborative program of research carried out under this award has exceeded all key guidelines laid out in the original proposal. It first has provided a new means to utilize high performance semiconductor materials in an exceptionally low cost and robust form factor. The technology so engendered by these key materials discoveries, new means of manufacturing, and advanced systems level designs are establishing new benchmarks for reductions in the installed cost/kWh relative to any commercial photovoltaic (PV) energy technology currently in use. The work in this program, having surpassed its key scientific milestones, has gone further and with our partners has now fully validated designs with scalable manufacturing methods for photovoltaic modules that use large-scale arrays of high efficiency solar microcells created from bulk wafers, integrating them in diverse spatial layouts on foreign substrates by transfer printing. Full research modules installed and operating at a utility site since 2010 have established the designs to be a viable PV technology.

36 MATERIALS SCIENCE↗
DOE OSTI2018

Quantitative Electroluminescence Imaging Analysis for Performance Estimation of PID-Influenced PV Modules

An empirical method for estimating relative power losses caused by potential-induced degradation (PID) for p-type solar cells and modules using quantitative electroluminescence (EL) analysis (QELA) is presented. First, EL images are corrected for camera- and perspective distortion. The relative power loss map is then calculated from the logarithmic ratio of two EL images, taken either before and after PID degradation or at different applied currents. Only the cell average of the resulting power loss map is evaluated. The highest power loss across each string is averaged to obtain the overall power loss. Consequently, for modules with three strings, three cells are averaged. The resulting power loss depends on the current applied. The conversion to equivalent irradiance allows for comparison of measured and estimated device performance. The analysis of roughly 2000 EL images and related current-voltage (I-V) curves indicates a good agreement between flash-test-measured and performance estimated using QELA. A relative root mean square error of 1-3% can be achieved.

14 SOLAR ENERGY↗
DOE OSTI2025

Reducing module soiling with scalable and robust photocatalytic coatings

The air-glass interface at the front of a photovoltaic (PV) module reflects approximately 4% of incident light, decreasing the potential power output of the module by the same amount. Today’s modules reduce this loss by adding a low-refractive-index (1.25-1.30) SiO2 coating to the sunward side of the module glass; this antireflection coating recovers approximately 3% of the 4% light that would otherwise be lost. While such antireflection coatings work very well on clean, new modules, they do not inhibit soiling—the accumulation of soilants such as dust, pollen, soot, or other foreign material—on the module glass, and soilants reflect and scatter incident light. An improved coating would serve provide not only an antireflection effect, but also an anti-soiling effect. The goal of this project was to develop such a coating and provide a path for it to be manufactured in the U.S. The project successfully designed and fabricated coatings that provided >3% transmittance gain compared to bare glass (matching the performance of commercial antireflection coatings) and displayed anti-soiling behavior in standard laboratory soiling effects. This was achieved by using a Swift Coat proprietary coating deposition technique, aerosol impact-driven assembly (AIDA), to control the porosity and thus refractive index of coatings of photocatalytic materials—such as TiO2—that would otherwise increase (instead of decrease) reflection. These combined antireflection/anti-soiling coatings passed PV industry standard module reliability tests as well as coating-specific abrasion tests, showing that they have the durability needed for decades in the field. Swift Coat scaled the AIDA hardware and deposition process to make mini-modules that were monitored for nearly two years during field tests administered by a third party, as well as demonstrated scaling to the widths of full-sized modules. The fielded mini-modules outperformed reference modules (with commercial antireflection coatings) in two locations, providing a 1% absolute average performance boost and larger increases during periods of heavier soiling. Swift Coat’s cost analysis indicated a coating manufacturing cost below the sales price of today’s antireflection coatings. More than five module manufacturers sampled and assessed the coatings, and three provided letters of support. The coating developed in this project increases the energy output of PV modules, thereby decreasing the cost per kilowatt-hour of solar energy generated. Cheaper solar electricity benefits the public by accelerating the transition to a stable, affordable, carbon-free energy economy. In addition, for select applications in which PV modules are highly visible—such as on residential rooftops—the coating provides an aesthetic benefit because it stays cleaner than today’s modules. Finally, Swift Coat and its prospective customers are U.S. companies, and successful commercialization of this technology will provide U.S. jobs and a secure solar supply chain.

14 SOLAR ENERGY↗
DOE OSTI2023

PV Module BOM and Test Data

This dataset contains compiled results from annual PV Module Reliability Scorecards published by PV Evolution Labs – also known as PVEL. These scorecards show summary results of PV module testing performed by PVEL and name specific models of PV modules as "Top Performers" in various tests. Full details on testing, Top Performer status and other criteria for inclusion in Scorecards are documented in reports and online documentation available from https://www.modulescorecard.pvel.com. This dataset is not affiliated with PVEL and is intended only to simplify sorting and filtering Scorecard data and finding specific PV module models and Top Performer results. Note that data included in Scorecards has evolved over time, so not all data is available for all years, and testing protocols and Scorecard criteria have been changed over time.

14 SOLAR ENERGY↗
DOE OSTI2023

Reliability of tandem solar cells and modules: what's next?

Hybrid tandem photovoltaic (PV) technology development has gained momentum in the last few years. This has been motivated by a need to push module efficiencies beyond what is theoretically capable with single-junction technologies to further accelerate total global PV deployment. Significant advances have been made with multiple material systems achieving tandem efficiencies over 30% in the last decade. All of the highest record efficiencies have been from laboratory-scale devices, with areas of 1 cm2 or less. Interestingly, there are multiple material combinations and terminal configurations that have demonstrated promising results. Despite these high laboratory efficiencies, reasonable service lifetimes (a useful operating lifetime of at least 25 years) are needed for tandems to compete with the levelized cost of energy (LCOE) of traditional single junction PV technologies. Existing commercial Si PV products have demonstrated performance in the field with an average of less than 1% relative annual degradation in module and system performance, and many manufacturers now provide 30 year warranties on their products.

14 SOLAR ENERGY↗