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At least 19 records

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DOE OSTI2020

The Abrasion of Photovoltaic Glass: A Comparison of the Effects of Natural and Artificial Aging

14 SOLAR ENERGY↗

DOE OSTI2024

Soiling, cleaning, and abrasion: The results of the 5-year photovoltaic glass coating field study

Not Available

Bomber, Joanna↗

DOE OSTI2018

Soiling Related Abrasion and the Development of a PV Abrasion Standard

The natural soiling and consequent cleaning of photovoltaic (PV) modules result in abrasion damage to the cover glass. The durability of the front glass has important economic consequences, including the use of antireflective and/or antisoiling coatings as well as the method and frequency of cleaning-maintenance. The abrasion of glass and coated glass has been explored in a field study, including the soiling-prone locations of: Dubai (United Arab Emirates), Kuwait city (Kuwait), Mesa (Arizona), Mumbai (India), and Sacramento (California). Dry brush cleaned specimens will be compared to those subject to artificial brush testing or falling sand abrasion. The characteristics of material integrity, optical transmittance, surface energy, surface roughness, and scratch size were examined using an optical microscope, spectrophotometer, contact goniometer (for water), interferometer, and atomic force microscope, respectively. The findings of this study will be used to provide feedback regarding the cleaning equipment, cleaning methods, and coatings used in the PV industry. The study here will also be used to aid the development of an abrasion standard for the PV industry.

14 SOLAR ENERGY↗

DOE OSTI2019

Decreasing the Impact–Abrasive Wear of Steel

A new method of assessing the impact–abrasive resistance of steel permits simulation of the impact–abrasive wear with variation in the magnitude and inclination of the impact force, type of abrasive, and its grain size and rate of consumption. The influence of five carbide-forming elements on the properties of the cast and quenched steel is studied: specifically, attention focuses on the abrasion resistance, impact–abrasive resistance, and hardness of the steel. Optimal steel compositions with abrasion resistance and impact–abrasive resistance greater than that of 35GL steel are identified.

42 ENGINEERING↗

DOE OSTI2017

Micro-Abrasion Wear Resistance of Borided 316L Stainless Steel and AISI 1018 Steel

The 316L stainless steel has high corrosion resistance but low tribological performance. In different industrial sectors (biomedical, chemical, petrochemical, and nuclear engineering), improvement upon wear resistance of 316L stainless steel components using accessible and inexpensive methods is critical. The AISI 1018 steel is widely used in industry, but its tribological performance is not the best among steels. Therefore, in this study the behavior of the borided 316L stainless steel and 1018 steel is evaluated under micro-abrasion wear. The boriding was carried out at 1223 K over 6 h of exposure time, resulting in a biphase layer composed of FeB/Fe{sub 2}B phases. In order to evaluate Fe{sub 2}B phase with no influence from FeB phase, AISI 1018 steel samples were borided at 1273 K for over 20 min and then diffusion annealed at 1273 K over 2 h to obtain a Fe{sub 2}B mono-phase layer. Micro-abrasion wear resistance was evaluated by a commercial micro-abrasion testing rig using a mix of F-1200 SiC particles with deionized water as abrasive slurry. The obtained wear rates for FeB and Fe{sub 2}B phases and for the 316L stainless steel were compared. Wear resistance of 316L stainless steel increases after boriding. The wear mechanisms for both phases and for the stainless steel were identified. Also, transient conditions for rolling and grooving abrasion were determined for the FeB and Fe{sub 2}B phases.

36 MATERIALS SCIENCE↗

DOE OSTI2020

Artificial linear brush abrasion of coatings for photovoltaic module first-surfaces

Natural soiling and the subsequent necessary cleaning of photovoltaic (PV) modules result in abrasion damage to the cover glass. The durability of the front glass has important economic consequences, including determining the use of anti-reflective and/or anti-soiling coatings as well as the method and frequency of operational maintenance (cleaning). Artificial linear brush abrasion using Nylon 6/12 bristles was therefore examined to explore the durability of representative PV first-surfaces, i.e., the surface of a module incident to direct solar radiation. Specimens examined include silane surface functionalized-, roughened (etched)-, porous silica-coated-, fluoropolymer-coated-, and ceramic (TiO 2 or ZrO 2 /SiO 2 /ZrO 2 /SiO 2 )-coated-glass, which are compared to monolithic-poly(methyl methacrylate) and -glass coupons. Characterization methods used in this study include: optical microscopy, ultraviolet–visible–near-infrared (UV-VIS-NIR) spectroscopy, sessile drop goniometry, white-light interferometry, atomic force microscopy (AFM), and depth-profiling X-ray photoelectron spectroscopy (XPS). The corresponding characteristics examined include: surface morphology, transmittance (i.e., optical performance), surface energy (water contact angle), surface roughness, scratch width and depth, and chemical composition, respectively. The study here was performed to determine coating failure modes; identify characterization methods that can detect nascent failures; compare the durability of popular contemporary coating materials; identify their corresponding damage characteristics; and compare slurry and dry-dust abrasion. This study will also aid in developing an abrasion standard for the PV industry.

14 SOLAR ENERGY↗

DOE OSTI2024

"Soiling, Cleaning, and Abrasion: The Results of the Five-Year Photovoltaic Glass Coating Field Study" [Slides]

External contamination ("soiling") of the incident surface is a major limiting factor for solar technologies. A 5-year field glass coupon study was conducted to better understand external contamination and its effects; compare cleaning methods and the use of preventative coatings; and explore the abrasion resulting from cleaning to advise on accelerated abrasion testing. Test sites included the cities of Dubai (UAE), Kuwait City (Kuwait), Mesa (AZ), Mumbai (India), and Sacramento (CA). Through the 5-year cumulative study, dry brush, water spray, and wet sponge and squeegee cleaning methods were compared to no cleaning. Optical microscopy was used to obtain images, including representative color images, grayscale images for object analysis, and oblique images for coating integrity assessment. A thresholding protocol was developed to analyze and distinguish specimens using the ImageJ software. Optical performance was quantified using a spectrophotometer, including comprehensive optical characterization (transmittance, reflectance, and absorptance in addition to forward- and back-scattering). Atomic force microscopy was used to verify the abrasion damage morphology, including the width and depth of surface scratches. Analysis of the results included correlation of optical performance and particle area coverage, rank order (by coating or location), and the acceleration factor for abrasion damage. The efficacy of external cleaning was more readily distinguished from the effectiveness of antisoiling coatings. The acceleration factor for dry brush cleaning of a porous silica coating was found to be on the order of unity.

14 SOLAR ENERGY↗

DOE OSTI2019

Finishing with Free and Bound Abrasive

Abrasive finishing of a single crystal by means of free and bound abrasive is compared in conditions with forced and free workpiece rotation. Experimental data show that the influence of forced and free workpiece rotation is different for finishing by means of free and bound abrasive. In machining by bound abrasive with forced rotation, the cutting rate and productivity are 25% higher, on average, than with free rotation.

36 MATERIALS SCIENCE↗

DOE OSTI2021

Artificial Linear Brush Abrasion of Coatings for Photovoltaic Module First Surfaces

Natural soiling and the subsequent requisite cleaning of photovoltaic (PV) modules result in abrasion damage to the cover glass. The durability of the front glass has important economic consequences, including determining the use of anti-reflective and/or anti-soiling coatings as well as the method and frequency of operational maintenance (cleaning). Artificial linear brush abrasion using Nylon 6/12 bristles was therefore examined to explore the durability of representative PV first-surfaces, i.e., the surface of a module incident to direct solar radiation. Specimens examined include silane surface functionalized-, roughened (etched)-, porous silica-coated-, fluoropolymer-coated-, and ceramic (TiO2 or ZrO2/SiO2/ZrO2/SiO2)-coated-glass, which are compared to monolithic-poly(methyl methacrylate) and -glass coupons. Characterization methods used in this study include: optical microscopy, ultraviolet-visible-near-infrared (UV-VIS-NIR) spectroscopy, sessile drop goniometry, white-light interferometry, atomic force microscopy (AFM), and depth-profiling X-ray photoelectron spectroscopy (XPS). The corresponding characteristics examined include: surface morphology, transmittance (i.e., optical performance), surface energy (water contact angle), surface roughness, scratch width and depth, and chemical composition, respectively. The study here was performed to determine coating failure modes; identify characterization methods that can detect nascent failures; compare the durability of popular contemporary coating materials; identify their corresponding damage characteristics; and compare slurry and dry-dust abrasion. This study will also aid in developing an abrasion standard for the PV industry.

41 EE - Solar Energy Technologies Office (EE-4S)↗

DOE OSTI2016

Review of Artificial Abrasion Test Methods for PV Module Technology

This review is intended to identify the method or methods--and the basic details of those methods--that might be used to develop an artificial abrasion test. Methods used in the PV literature were compared with their closest implementation in existing standards. Also, meetings of the International PV Quality Assurance Task Force Task Group 12-3 (TG12-3, which is concerned with coated glass) were used to identify established test methods. Feedback from the group, which included many of the authors from the PV literature, included insights not explored within the literature itself. The combined experience and examples from the literature are intended to provide an assessment of the present industry practices and an informed path forward. Recommendations toward artificial abrasion test methods are then identified based on the experiences in the literature and feedback from the PV community. The review here is strictly focused on abrasion. Assessment methods, including optical performance (e.g., transmittance or reflectance), surface energy, and verification of chemical composition were not examined. Methods of artificially soiling PV modules or other specimens were not examined. The weathering of artificial or naturally soiled specimens (which may ultimately include combined temperature and humidity, thermal cycling and ultraviolet light) were also not examined. A sense of the purpose or application of an abrasion test method within the PV industry should, however, be evident from the literature.

14 SOLAR ENERGY↗

DOE OSTI2017

Automated instrument for assessing abrasives

An automated instrument for monitoring the destructive compressive load on abrasive grains (measuring 400–1250 μm) between two rotating rollers has been developed. A modernized version of the instrument also permits determination of the grain size, shape, and microgeometric and topographic characteristics of abrasives. Equipped with a photometric unit and a module for processing numerical information, the modernized instrument permits multiple recording of each particle by six cameras (in both directions along three orthogonal axes), with assessment of the microgeometry. Such information regarding the grains, along with identification of their shape (plates, needles, isometric form, etc.), permits their quality assessment; their subsequent separation on vibrational sorters; and their most effective use in the abrasive machining of materials characterized by different hardness, brittleness, and composition, including composites.

36 MATERIALS SCIENCE↗

DOE OSTI2024

Abrasive Waterjet Machining

The abrasive waterjet machining process was introduced in the 1980s as a new cutting tool; the process has the ability to cut almost any material. Currently, the AWJ process is used in many world-class factories, producing parts for use in daily life. A description of this process and its influencing parameters are first presented in this paper, along with process models for the AWJ tool itself and also for the jet–material interaction. The AWJ material removal process occurs through the high-velocity impact of abrasive particles, whose tips micromachine the material at the microscopic scale, with no thermal or mechanical adverse effects. The macro-characteristics of the cut surface, such as its taper, trailback, and waviness, are discussed, along with methods of improving the geometrical accuracy of the cut parts using these attributes. For example, dynamic angular compensation is used to correct for the taper and undercut in shape cutting. The surface finish is controlled by the cutting speed, hydraulic, and abrasive parameters using software and process models built into the controllers of CNC machines. In addition to shape cutting, edge trimming is presented, with a focus on the carbon fiber composites used in aircraft and automotive structures, where special AWJ tools and manipulators are used. Examples of the precision cutting of microelectronic and solar cell parts are discussed to describe the special techniques that are used, such as machine vision and vacuum-assist, which have been found to be essential to the integrity and accuracy of cut parts. The use of the AWJ machining process was extended to other applications, such as drilling, boring, milling, turning, and surface modification, which are presented in this paper as actual industrial applications. To demonstrate the versatility of the AWJ machining process, the data in this paper were selected to cover a wide range of materials, such as metal, glass, composites, and ceramics, and also a wide range of thicknesses, from 1 mm to 600 mm. The trends of Industry 4.0 and 5.0, AI, and IoT are also presented.

36 MATERIALS SCIENCE↗

DOE OSTI2018

Investigations on microstructure, mechanical properties and abrasion resistance of 4wt%Cr-2wt%Mn-2wt%Cu-Fe-B alloy

Highlights: • The microstructure mainly consists of martensite and boride (M{sub 2}B) in the as-cast and heat treated Fe-B alloys, and the M{sub 2}B presents 3D-skeleton continuous-distribution. • After heat treatment, the nucleation and precipitation of secondary borocarbide M{sub 23}(C, B){sub 6} probably take place in an in situ manner within martensite. • The matrix hardness and bulk hardness of Fe-B alloy decrease after heat treatment, this is attributed to the decreasing of B/C concentration of matrix caused by the precipitation of M{sub 23}(C, B){sub 6}. • During the two-body wear process, the wear mechanism of Fe-B alloy is microcutting; with decreasing of hardness of Fe-B alloy, the abrasion resistance of Fe-B alloy decreases, i.e. the heat treatment will decrease the abrasion resistance of Fe-B alloy. - Abstract: The microstructure, mechanical properties and abrasion resistance of Fe-B alloy with 4wt%Cr-2wt%Mn-2wt%Cu addition have been systematically investigated. The results show that the microstructures mainly consist of martensite and boride (M{sub 2}B) in the as-cast and heat treated Fe-B alloys; after heat treatment, the morphology and volume fraction of the M{sub 2}B have little change, meanwhile the nucleation and precipitation of secondary borocarbide M{sub 23}(C, B){sub 6} probably take place in an in situ manner within martensite. Moreover, the M{sub 2}B is identified as chemical formula of Fe{sub 2.04}Cr{sub 0.11}Mn{sub 0.07}(B, C) reflecting body-centred tetragonal (bct) structure, and the secondary borocarbide M{sub 23}(B, C){sub 6} has the stoichiometry of Fe{sub 18.84}Cr{sub 2.84}Mn{sub 0.57}(B, C){sub 6} with face-centred cubic (fcc) structure. After heat treatment, the matrix hardness and bulk hardness of Fe-B alloy decrease owing to the decreasing of B/C concentration of matrix caused by the precipitation of M{sub 23}(C, B){sub 6}, while the fracture toughness of Fe-B alloy increases. Meanwhile, the heat treatment will decrease the wear resistance of Fe-B alloy, i.e. the wear resistance of Fe-B alloy would decrease with reduction of the matrix hardness.

36 MATERIALS SCIENCE↗

DOE OSTI2021

Wear in particle based CSP systems from particle abrasion and attrition at high temperature

High temperature particle-based receivers offer distinct advantages over conventional molten salt receivers due to their ability to achieve temperatures above 700 ºC, direct absorption of solar energy as they fall through a beam of concentrated sunlight, and the relative ease of storage (and retrieval using a secondary working fluid) in insulated storage tanks. The use of particles, however, also raises concerns with material degradation from the flow of hot or cold particles through discharge hoppers or along the inner receiver surfaces and other system components (e.g. tubes, valves etc.), depending on operating mode of the receiver. The flow of particles over surfaces may result in loss of material from abrasive wear, impact erosion from impingement under gravitational fall and particle attrition as particles fall and move on top of each other. In the present study, the performance of candidate materials and particles were evaluated through a series of abrasion erosion and particle attrition experiments at room temperature as well as at 800 °C. Candidate materials were subject to abrasive wear from particles at low particle to material velocities inside a resistance heated kiln, and analyzed for changes in mass and surface morphology using cross-sectional scanning electron microscopy (SEM) and energy dispersive x-ray spectroscopy (EDS) tests. The wear rate for different specimens was noted to be largely driven by the strength of chromia scales built on the specimens from exposure to high temperature. Particle attrition measurements explored the susceptibility of particles to breakdown from particle to particle interaction and the generation of fines from this process. At the low velocities expected in particle based CSP plants, the particles tested exhibited near negligible breakdown. However, changes in the particle hardness at 800 ºC resulted in a significantly higher particle breakdown to sizes <40 microns raising potential environmental concerns. In addition to particle breakdown, it was also noted that the sample had oxides from the stainless steel test setup mixed in with the particles. Similar oxides can be expected to turn up in the utility scale particle based CSP plants as well. The presence of oxide was also noted to affect the solar absorptivity of the mixture compared to a clean initial specimen, potentially resulting in a change in the overall efficiency of the CSP plant.

14 SOLAR ENERGY↗

DOE OSTI2021

Abrasion wear at high temperature in particle receiver type Concentrating Solar Power Systems

The use of solid particles as a heat transfer fluid in receivers for concentrating solar powerplants has garnered much attention in the past decade. Particles are not only stable at temperatures above 700 °C but are also able to absorb solar energy directly, which gives them a distinct advantage over conventional molten salts. The use of particles can, however, cause material degradation from the flow of hot or cold particles through discharge hoppers or along the inner receiver surfaces and other system components (e.g. tubes, valves etc.), depending on operating mode of the receiver. Stainless steel alloy 316, nickel-based alloy Inconel® 740H®, Haynes 230, and a 60% alumina, low-cement refractory castable from Allied Mineral Products were tested for wear from first-of-a-kind high-temperature low-velocity abrasion-erosion experiments. The tests are designed to simulate potential conditions in Generation 3 falling particle Concentrating Solar Power (CSP) systems. Simultaneous experiments were conducted at room temperature as well to draw comparison on the role of temperature on abrasion wear rates. It was noted that the abrasion wear rate in candidate materials was driven by the oxidation resistance of the material. The findings from these experiments will be used to determine life-time of critical components in particle receiver concentrated solar powerplants.

14 SOLAR ENERGY↗

DOE OSTI2018

Weatherable solar reflector with high abrasion resistance

Described herein are solar reflectors which provide a low cost reflector construction that has a unique set of attributes: high solar reflectance, abrasion resistance, UV stability, mechanical integrity, and flexibility. The abrasion resistance is enabled through incorporation of an abrasion-resistant coating into a polymer film metal mirror construction. Methods of using the solar reflectors in solar concentrating applications are also provided.

14 SOLAR ENERGY↗

DOE OSTI2019

Microstructural Analysis of Powder Metallurgy Tool Steels in the Context of Abrasive Wear Behavior: A New Computerized Approach to Stereology

The present work describes a new methodology designed to characterize the microstructures of tool steels containing carbide hard phases, with the focus set on their abrasive wear resistance. A series of algorithms were designed and implemented in MATLAB® to (i) recognize each of the features of interest, (ii) measure relevant quantities and (iii) characterize each of the phases and the alloy in function of attributes usually neglected in wear description applications: size distribution, shape and contiguity of the hard phases. The new framework incorporates new parameters to describe each one of these attributes, as observed in SEM micrographs. All three aforementioned stages contain novel contributions that can be potentially beneficial to the field of materials design in general and to the field of alloy design for severely abrasive environments in particular. Models of known geometry and micrographs of different powder metallurgy steels were analyzed, and the obtained results were compared with the obtained by the linear intercept method. The relation between the new parameters and the ones available in the scientific literature is also discussed.

36 MATERIALS SCIENCE↗

DOE OSTI2018

Effect of Abrasion on the Crystal Structure of ZnS and ZnSe Ceramics

Zinc sulfide and zinc selenide ceramic samples prepared by hot pressing (HP) and chemical vapor deposition (CVD) have been subjected to dry grinding simulating dust erosion of these materials under real service conditions. It has been demonstrated that photoluminescence measurements allow one to follow the degradation of the crystal structure of ceramic grains by monitoring the intensity of structure-sensitive emission bands. The crystal structure of ZnS, a harder material, has been shown to be less sensitive to abrasion. Moreover, the abrasion resistance of the ceramics produced by CVD exceeds that of the HP ceramics of the same composition.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗