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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 19 records
All sourcesNASA NTRSDOE OSTI
DOE OSTI2024

Optimized Floating Offshore Wind Turbine Substructure Design Trends for 10–30 MW Turbines in Low-, Medium-, and High-Severity Wave Environments

Floating offshore wind is a promising renewable energy source, as 60% of the wind resources globally are found at depths requiring floating technologies, it minimizes construction at sea, and provides opportunities for industrialization given a lower site dependency. While floating offshore wind has numerous advantages, a current obstacle is its cost in comparison to more established energy sources. One cost-reduction approach for floating wind is increasing turbine capacities, which minimizes the amount of foundations, moorings, cables, and O&M equipment. This work presents trends in mass-optimized VolturnUS hull designs as turbine capacity increases for various wave environments. To do this, a novel rapid hull optimization framework is presented that employs frequency domain modeling, estimations of statistical extreme responses, industry constructability requirements, and genetic algorithm optimization to generate preliminary mass-optimal VolturnUS hull designs for a given turbine design and set of site conditions. Using this framework, mass-optimized VolturnUS hull designs were generated for 10–30 MW turbines for wave environments of varying severities. These design studies show that scaling up turbine capacities increases the mass efficiency of substructure designs, with decreasing returns, throughout the examined turbine capacity range. Additionally, increased wave environment severity is shown to increase the required mass of a given substructure design.

VolturnUS↗
DOE OSTI2025

Implementation of tritium transport in a gas-liquid contactor CFD simulation of tritium extraction from lead-lithium in ANSYS fluent

Modifications to the Computational Fluid Dynamic (CFD) software ANSYS Fluent were done to quantify and characterize tritium transport in Gas-Liquid Contactors (GLCs). A double-slit, Ergun-like equation was employed for the porous media model, with Ergun coefficients validated with Sulzer’s Sulcol software. Tritium transport from PbLi within the GLC was verified against analytical models. The geometry of the CFD model was based on the MELODIE GLC experiment. The hydrodynamic CFD pressure drop results align well with SulCol estimations and fall between the predictions of the analytical Delft-Olujic and Billet & Schultes models. In terms of mass transfer efficiency, traditional mass transfer models showed a significant deviation from experimental results when using varying values of H solubility in PbLi. A saturation phenomenon occurred when utilizing high solubility values for hydrogen in PbLi. In conclusion, a modified film theory mass transfer coefficient, incorporating either the Delft-Olujic or Billet & Schultes wettability model, yielded CFD-predicted extraction efficiencies that closely matched experimental measurements.

70 - PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2025

Ambient Rare Earth Metal Electrodeposition in Nitrogen-Coordinated Silylamide Electrolyte

The transition to a sustainable, low-carbon economy demands energy-efficient and environmentally benign methods for rare earth metal (REM) production. Furthermore, while high-temperature molten salt electrolysis remains energy-intensive, corrosive, and environmentally unfriendly, emerging room-temperature processes based on conventional ionic liquids are also hindered by high viscosity and chemical instability. In this study, a nitrogen-coordinated, water-, oxygen-, and fluorine-free silylamide-based electrolyte is presented as a promising system for room-temperature REM electrodeposition. Derived from commercially available lithium silylamide precursors, the system enables facile synthesis, broad electrochemical stability, and tunable metal–ligand interactions. Electrochemical analysis reveals high voltammetric stripping reversibility, stable cathodic and anodic potentials, and selective neodymium (Nd) deposition at appreciable current densities (>1 mA/cm 2 ), with minimal parasitic reactions. Bulk experiments produced high-purity Nd with reproducible performance across multiple batches. Scaled deposition yielded over 1 g of Nd with near-theoretical mass efficiency (0.40 mg/C) and >90% purity. Using sacrificial dysprosium (Dy) and Nd metal anodes, the system maintained constant Nd loading during extended deposition and enabled cathodic codeposition of stripped anode material, demonstrating the electrolyte’s dual functionality for REM electrorefining. Collectively, this silylamide platform offers a compelling combination of electrochemical robustness, chemical resilience, and process scalability for sustainable ambient REM recovery.

36 - MATERIALS SCIENCE↗
DOE OSTI2025

Breaking the Linear Scaling Relations for the Oxygen Reduction Reaction with a Dual‐Atom Catalyst Composed of a MnFe‐Porphyrrole Aerogel

Bimetallic catalysts offer enhanced catalytic performance through synergistic interactions between the two metals, allowing them to break the linear scaling relations and reach high electrocatalytic activity. This study presents bimetallic aerogel-based catalyst synthesized as a covalent, three-dimensional framework containing neighboring iron and manganese sites. The aerogel structure provides a high surface area and porosity, facilitating an ultra-high active site density and efficient mass transport. The MnFe porphyrrole's unique structure is obtained by alternately linking Mn-porphyrin and Fe-corrole complexes. It exhibited outstanding performance with an onset potential of 0.99 V RHE . Comparative studies with a free-base Fe porphyrrole catalyst (E onset 0.97 V RHE ) revealed that while Mn incorporation led to only a slight improvement in half-cell performance, it resulted in significantly enhanced performance in anion exchange membrane fuel cell. The MnFe catalyst achieved an OCV of 0.97 V and a peak power density of 0.27 W cm −2 , outperforming the free-base Fe counterpart. Using density functional theory calculations, we show that the higher ORR activity of MnFe-porphyrrole is due to charge transfer between Mn and Fe atoms, which is absent in the reference free-base Fe-porphyrrole. These findings underscore the advantages of bimetallic catalysts in improving ORR activity and fuel cell efficiency by leveraging synergistic effects.

Aerogel↗
DOE OSTI2026

Evaluating Polymer Properties with Different Additives for Carbon Capture and Other Applications

Anthropogenic climate change is one of this generation’s most pressing concerns, with the potential to completely alter the delicate balance we’ve struck with nature. Already, global temperatures have risen 1.29°C, leading to disrupted weather systems, extinctions, increased risks of wildfires, and sea level rise, to name a few effects. Carbon dioxide emission from the combustion of fossil fuels and other industrial activity is a large driver of this phenomenon, as it absorbs heat before it can be radiated away from Earth, trapping it. Carbon dioxide has reached unprecedented levels in our atmosphere, showing a 50% increase from preindustrial averages to a whopping 430 ppm. Thus, reducing the amount of carbon dioxide via carbon capture technology is an important endeavor that serves to benefit everyone. The Microencapsulated CO 2 Sorbent (MECS) team at Lawrence Livermore National Laboratory (LLNL) has turned to microencapsulation to approach this endeavor. Microcapsules provide an attractive approach to carbon capture, combining large surface areas for more efficient mass transfer, regenerative abilities, reduced solvent loss, and improved handling. Additionally, while existing carbon capture technology relies on industrial plants, capsules could present a modular approach to carbon capture, reducing the need for extensive physical infrastructure. The MECS team’s design consists of a polymer membrane that contains a liquid carbon sequestering sorbent, aqueous sodium carbonate. The carbon capturing reaction occurs in three distinct steps, the first of which is the dissolution of carbon dioxide into the sorbent solution and its conversion into carbonic acid (H 2 CO 3 ), shown in equations 1 and 2 respectively. Because this step hinges upon the ability of carbon dioxide to reach the solution inside the capsule, it is necessary that the microcapsule shell is permeable to carbon dioxide gas. The MECS team produces these microcapsules using the in-air droplet encapsulation apparatus (IDEA) shown in figure 1, which can produce uniform micron-scale droplets at speeds much faster than traditional single-dispersal microfluidic-based techniques. The IDEA Is 100 times faster than these current techniques and can reach up to 1000 times their speed when incorporating a multi-nozzle design. Additionally, because droplets are produced in-air via vibration, IDEA can decrease post-processing times and material waste by 99% and can fabricate microgels that are 10 to 100 times more viscous than can be produced via traditional microfluidics. While this design represents a breakthrough in the throughput, efficiency, and tunability of microcapsule production, it imposes a major constraint on the microcapsule curing process. Because microcapsule shells are crosslinked with UV light while falling 30 cm through the air, this gives them a reaction window of approximately 0.2 seconds. Thus, the system and shell formulations must be optimized such that the shells can be fully crosslinked within this very narrow window, prompting investigations into curing behavior.

36 MATERIALS SCIENCE↗
DOE OSTI2024

Hierarchically Structured Catalysts Toward Sustainable Hydrogen Economy: Electro‐ and Thermo‐Chemical Pathways

Abstract Hydrogen, as an important clean energy source, plays a more and more crucial role in decarbonizing the planet and meeting the global climate challenge due to its high energy density and zero‐emission. The demand for sustainable hydrogen is increasing drastically worldwide as driven by the global shift towards low‐carbon energy solutions. Thermochemical catalysis process dominates hydrogen production at scale given its relatively mature technology and commercialization status, as well as the established manufacturing infrastructure. While due to its environmentally friendly nature and growing abundant sources of renewable electricity, the electrochemical path for hydrogen production is rising as a major alternative to the thermochemical means. Nevertheless, hierarchically structured catalysts and devices have gradually taken the center stage toward replacing the traditional counterparts, especially with the rapid advancement of the design and manufacture of such ordered nanostructure assemblies toward high activity, efficient mass transport, and superb stability. In this review, the latest progress of the hierarchically structured catalysts for hydrogen production have been surveyed on electro‐ and thermo‐ chemical pathways comparatively. It covers the structure designs of atomic dispersion, nanoscale surfaces and interfaces for achieving highly active and durable catalysts, components, and devices. Both electrochemical and thermochemical approaches are reviewed in terms of the vast design details, engineered benefits, and understandings of various Pt‐group metal (PGM) and non‐PGM based transition metal catalysts for hydrogen production. As the growing trend, brief discussions are also presented toward the high‐level assembly and manufacture of complexly structured components and devices at scale in the electrochemical and thermochemical energy systems.

Deng, Chenxin↗
DOE OSTI2024

Direct Air Capture Recovery of Energy for CCUS Partnership (DAC RECO 2 UP) Final Technical Report

The “Direct Air Capture Recovery of Energy for CCUS Partnership (DAC RECO 2 UP)” project employs a team approach and supports the U.S. Department of Energy Office of Fossil Energy and Carbon Management’s (DOE-FECM) goal to decrease the cost of capture through the testing of existing direct air capture (DAC) materials in integrated field units that produce a concentrated carbon dioxide (CO 2 ) stream of at least 95% purity. Solid-amine CO 2 adsorption-desorption contactor technology, proven in the laboratory, is undergoing high-fidelity design/validation. Recoverable energy is readily available from a large number of commercial locations where DAC can be deployed; therefore, advancing the fidelity of energy recovery to directly reduce the cost of DAC is a key project objective. In addition, many commercial facilities have low-concentration CO 2 vents that are uneconomical to treat alone but could provide more efficient mass and thermal transport to DAC systems with integrated energy recovery and flexible CO 2 treatment capabilities. Technology scale-up leverages past research and occurs in a commercially relevant environment at the National Carbon Capture Center. Prescreening techno-economic analysis, risk assessments, and life cycle analysis are being performed by experienced team members. Results of the project will address critical technical barriers that, when solved, will improve the capital and operating costs of DAC while validating commercial relevance of cost and product quality/need.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2025

Development and investigation of efficient resonance ionization mass spectrometry schemes of gadolinium

Resonance ionization mass spectrometry of gadolinium can be used for nuclear forensics and to further the understanding of stellar nucleosynthesis but has been used only a handful of times due to the high laser power required and interference from non-resonant ionization of molecules of other elements. Herein we present the development of two novel resonance ionization spectroscopy schemes for gadolinium that provide improvements in isotopic fractionation and ionization efficiency, respectively, opening new applications for gadolinium analysis. The schemes are demonstrated and compared in a mixed sample of gadolinium and neodymium.

and nuclear chemistry↗
DOE OSTI2025

Low-Mass and High-Efficiency Engine for Medium-Duty Truck Applications

This collaborative multi-year advanced engine technology project summarized in the report is to develop low mass and high efficiency medium-duty truck engine. The project was proposed as a large-scale engine design and demonstration enabled by an advanced materials and manufacturing development program, with a comprehensive plan spanning a period of four years (two phases).

33 ADVANCED PROPULSION SYSTEMS↗
DOE OSTI2025

Techno-Economic Analysis of Gas-Liquid Contactors for Tritium Extraction from Lead-Lithium

To enable a sustainable fuel cycle, any deuterium-tritium fusion reactor must breed its tritium fuel onsite. Lead-lithium (PbLi), a eutectic metal, is a leading liquid breeder material for tritium generation. One challenge with PbLi blanket technology is the extraction of tritium from the molten eutectic. Three technologies are the focus of worldwide research: the vacuum permeator, the vacuum sieve tray, and the gas-liquid contactor (GLC). The present work offers a methodology for designing, sizing, optimizing, and costing a trickle-bed GLC. Here, we analyzed tritium extraction from PbLi using MELODIE experimental data by applying traditional packed bed mass transfer efficiency models along with supplementary models, like film theory. Our analysis revealed that traditional packed bed mass transfer efficiency models do not fit the MELODIE loop experimental data. Moreover, uncertainty in PbLi solubility resulted in a 325-fold increase in required gas flow rates when comparing identical packing heights. The film theory liquid mass transfer coefficient, Delt-Olujic wettability model, and Reiter tritium solubility values fit the MELODIE data best and were used both in the design and to conduct the economic analysis. Techno-economic analysis of the GLC was performed to evaluate three design sizes, all achieving a minimum extraction efficiency of 90 [%] for a total tritium extraction of 31 [kg/yr].

Fusion Fuel Cycle↗
DOE OSTI2024

Anticipating how rain-on-snow events will change through the 21st century: lessons from the 1997 new year’s flood event

The California-Nevada 1997 New Year’s flood was an atmospheric river (AR)-driven rain-on-snow (RoS) event and remains the costliest in their history. The joint occurrence of saturated soils, rainfall, and snowmelt generated inundation throughout northern California-Nevada. Although AR RoS events are projected to occur more frequently with climate change, the warming sensitivity of their flood drivers across scales remains understudied. We leverage the regionally refined mesh capabilities of the Energy Exascale Earth System Model (RRM-E3SM) to recreate the 1997 New Year’s flood with horizontal grid spacings of 3.5 km across California, with forecast lead times of up to 4 days, and across six warming levels ranging from pre-industrial conditions to +3.5° C. We describe the sensitivity of the flood drivers to warming including AR duration and intensity, precipitation phase, intensity and efficiency, snowpack mass and energy changes, and runoff efficiency. Our findings indicate current levels of climate change negligibly influence the flood drivers. At warming levels ≥ 1.7° C, AR hazard potential increases, snowpack nonlinearly decreases, antecedent soil moisture decreases (except where the snowline retreats), and runoff decreases (except in the southern Sierra Nevada where antecedent snowpack persists). Storm total precipitation increases, but at rates below warming-induced increases in saturation-specific humidity. Warming intensifies short-duration, high-intensity rainfall, particularly where snowfall-to-rainfall transitions occur. This study highlights the nonlinear tradeoffs in 21st-century RoS flood hazards with warming and provides water management and infrastructure investment adaptation considerations.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2025

24.1.3.4 Upgraded Fixed Energy Response Function Analysis with Multiple Efficiencies (FRAM) Software for U/Pu/MOX Mass Measurements

Fixed-energy Response-function Analysis with Multiple efficiency (FRAM) is a software code designed primarily for plutonium and uranium isotopic analysis. It is widely used in both the domestic and international safeguards community. FRAM can quickly and accurately determine the isotopic compositions of plutonium, uranium, and mixed oxides (MOX) when measuring with a high-purity germanium (HPGe), cadmium zinc telluride (CZT), or lanthanum bromide (LaBr 3 ) detector. The capabilities of FRAM have been enhanced to analyze the data of the pixelated CZT detector (made by H3D) and to measure the mass of plutonium, uranium, and MOX. Both the isotopic composition and mass of the item can be quickly determined with one measurement using a gamma detector with FRAM v.7.1.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗
DOE OSTI2024

Advanced multimaterial shape optimization methods as applied to advanced manufacturing of wind turbine generators

Abstract Currently, many utility‐scale wind turbine generator original equipment manufacturers are dependent on imported rare earth permanent magnets, which are susceptible to market risks from cost instability. To lower the production costs of these generators and stay competitive in the market, several small wind manufacturers are pursuing continuous improvements to both generator design and manufacturing. However, traditional design and manufacturing methods have yielded marginal improvements in wind power performance. This work presents novel methods to redesign a baseline 15‐kW wind turbine generator with reduced rare‐earth permanent magnets by leveraging cutting‐edge three‐dimensional (3D) printed polymer‐bonded permanent magnets and steel. Symmetric, asymmetric, and multimaterial‐magnet parametrization methods are introduced for shape optimization. We extend the symmetric and asymmetric methods to the back iron in the stator to further investigate the impact and opportunities for performance improvements with lesser active materials. We employ a design‐of‐experiments approach with parametric computer‐aided design for shape generation and evaluate different designs by magneto‐thermal modeling and finite‐element analysis. We use adaptive sampling technique to identify better performing designs with lesser magnet mass, higher efficiency, and lower cogging torque when compared with the baseline generator. Asymmetric pole designs resulted in a magnet mass in the range of 4.77–5.37 kg, which was 27%–35% lighter than the baseline generator, suggesting that a new design freedom exists that can be enabled by advanced manufacturing, such as 3D printing. Shaping the back iron in the stator resulted in material savings in electrical steel of up to 14.62 kg, which was 20% lighter than the baseline stator. We conducted a structural analysis to evaluate an optimized asymmetric rotor design from the point of view of mechanical integrity and air‐gap stiffness. The magnetically optimal shape profile was shown as having a positive impact on the radial stiffness, and an optimal solution was discovered to reduce the structural mass by nearly 30 kg, which was 29% lighter than the baseline.

17 WIND ENERGY↗
DOE OSTI2025

Cu-, Co-, and Zn-Based Metal–Organic Framework-Derived Nanoporous Ion Emitters for Picogram Level Analysis of Actinides

Thermal ionization mass spectrometry (TIMS) is often regarded as the preferred technique for trace-level isotopic analysis of actinides owing to its high sensitivity and absence of carry-over effects. However, actinide sample utilization efficiency (SUE) is typically low (<0.05%) without the use of activators or specialized loading approaches which can yield SUEs of >5%. To this effect, we investigate a series of metal–organic framework (MOF)-based nanoporous ion emitters (nano-PIEs) that show enhanced ionization of actinides when used in TIMS loading. We study the impact of physical and chemical properties of MOFs on TIMS SUEs using two families of MOFs that can be synthesized under similar reaction conditions. The structural and chemical properties of these MOFs can be systematically modified one at a time while keeping other features the same. This allows us to strategically investigate their impact on SUEs. The first family of MOFs considered in this study is Zeolitic Imidazole Frameworks (ZIFs) which are made using 2 methyl-imidazole as an organic linker with zinc (ZIF-8) and cobalt (ZIF-67) as metal centers. Additionally, the effect of morphology was also studied using Zn-based ZIF-L with a 2-dimensional structure. The second family of MOFs was synthesized using benzene-1,3,5-tricarboxylate (BTC) with copper (Cu-BTC) and zinc (Zn-BTC) as the metal center. Among the MOFs tested, Cu-BTC showed the highest SUE with an average SUE of 0.27 ± 0.15%, followed closely by Zn-BTC (0.24 ± 0.10%), ZIF-8 (0.17 ± 0.10%), and trailed by the other MOFs. When the MOFs were pyrolyzed in N 2 before loading, an apparent increase in the SUE was observed with ZIF-8 and Cu-BTC showing average SUEs of 0.25 ± 0.08% and 0.34 ± 0.13%, respectively, with the highest measured SUE of 0.53% for pyrolyzed Cu-BTC. In conclusion, this observed increase in SUE by up to an order of magnitude compared to bare filaments demonstrates the efficacy and potential of MOF-derived nano-PIEs for TIMS application.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2024

Real-time signal detection for Cyclotron Radiation Emission Spectroscopy measurements using antenna arrays

Cyclotron Radiation Emission Spectroscopy (CRES) is a technique for precision measurement of the energies of charged particles, which is being developed by the Project 8 Collaboration to measure the neutrino mass using tritium beta-decay spectroscopy. Project 8 seeks to use the CRES technique to measure the neutrino mass with a sensitivity of 40 meV, requiring a large supply of tritium atoms stored in a multi-cubic meter detector volume. Antenna arrays are one potential technology compatible with an experiment of this scale, but the capability of an antenna-based CRES experiment to measure the neutrino mass depends on the efficiency of the signal detection algorithms. Here, in this paper, we develop efficiency models for three signal detection algorithms and compare them using simulations from a prototype antenna-based CRES experiment as a case-study. The algorithms include a power threshold, a matched filter template bank, and a neural network based machine learning approach, which are analyzed in terms of their average detection efficiency and relative computational cost. It is found that significant improvements in detection efficiency and, therefore, neutrino mass sensitivity are achievable, with only a moderate increase in computation cost, by utilizing either the matched filter or machine learning approach in place of a power threshold, which is the baseline signal detection algorithm used in previous CRES experiments by Project 8.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗
DOE OSTI2025

Biomass burning emission analysis based on MODIS aerosol optical depth and AeroCom multi-model simulations: implications for model constraints and emission inventories

We assessed the biomass burning (BB) smoke aerosol optical depth (AOD) simulations of 11 global models that participated in the AeroCom phase III BB emission experiment. By comparing multi-model simulations and satellite observations in the vicinity of fires over 13 regions globally, we (1) assess model-simulated BB AOD performance as an indication of smoke source–strength, (2) identify regions where the common emission dataset used by the models might underestimate or overestimate smoke sources, and (3) assess model diversity and identify underlying causes as much as possible. Using satellite-derived AOD snapshots to constrain source strength works best where BB smoke from active sources dominates background non-BB aerosol, such as in boreal forest regions and over South America and southern hemispheric Africa. The comparison is inconclusive where the total AOD is low, as in many agricultural burning areas, and where the background is high, such as parts of India and China. Many inter-model BB AOD differences can be traced to differences in values for the mass ratio of organic aerosol to organic carbon, the BB aerosol mass extinction efficiency, and the aerosol loss rate from each model. The results point to a need for increased numbers of available BB cases for study in some regions and especially to a need for more extensive regional-to-global-scale measurements of aerosol loss rates and of detailed particle microphysical and optical properties; this would both better constrain models and help distinguish BB from other aerosol types in satellite retrievals. More generally, there is the need for additional efforts at constraining aerosol source strength and other model attributes with multi-platform observations.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2024

Assay-based background projection for the Majorana Demonstrator using Monte Carlo uncertainty propagation

The background index (BI) is an important quantity to project and calculate the half-life sensitivity of neutrinoless double-𝛽 decay (0⁢𝜈⁢𝛽⁢𝛽) experiments. An analysis framework is presented to calculate the BI using the specific activities, masses, and simulated efficiencies of an experiments components as distributions. This Bayesian framework includes a unified approach to combine specific activities from assay. Monte Carlo uncertainty propagation is used to build a BI distribution from the specific activity, mass, and efficiency distributions. This method is applied to the M AJORANA D EMONSTRATOR , which deployed arrays of high-purity Ge detectors enriched in 76 Ge to search for 0⁢𝜈⁢𝛽⁢𝛽. The original assay-based projection is requantified in the new framework, using the as-built geometry of the Demonstrator and additional assay information. While 47% higher than the original projection, the resulting BI of [8.95±0.36]×10 −4 cts/(keVkgyr) from the 232 Th and 238 U decay chains does not account for the higher-than-expected BI observed by the D EMONSTRATOR . Finally, this method enables us to demonstrate the statistical incompatibility between the D EMONSTRATOR 's observed background and the assay results.

72 PHYSICS OF ELEMENTARY PARTICLES AND FIELDS↗
DOE OSTI2026

Identifying Suitable Front Contacts for High‐Efficiency Cd(Se,Te) Solar Cells on Space‐Qualified Cover Glass

Deployment of photovoltaics in space requires devices that combine high-efficiency, low areal mass, and resilience to harsh environments. Historically, high-efficiency multijunction III–V materials have dominated space power systems; however, their high cost and limited manufacturing throughput motivate the exploration of scalable alternatives. While CdTe-based thin-film photovoltaics offer an attractive option, their performance on non-conventional substrates can suffer from front contact instability under higher-temperature processing. Here, the role of front contact chemistry in limiting cell performance is investigated using CdTe-based devices fabricated on 150 μm thick Ceria-doped space-qualified 0214 Corning glass. A matrix of four transparent conducting oxides (TCOs: CTO, AZO, ITO, IZO) combined with two n-type emitters (MZO, IGO) reveals chemical stability at the front interface—rather than absorber composition alone—governs recombination losses, voltage deficits, and device reproducibility. Chemically stable front contact combinations suppress elemental diffusion and interfacial degradation, resulting in significantly improved carrier lifetimes and junction quality. These insights are validated through record-certified Cd(Se,Te) cell efficiencies of 18.4% under AM1.5G and 16.2% under AM0 illumination on ultra-thin glass. Beyond CdTe, this work provides a general framework for the rational selection of TCO/emitter interfaces in superstrate thin-film photovoltaics, including emerging technologies like metal halide perovskites, while enabling high-efficiency, lightweight photovoltaics for space applications.

14 SOLAR ENERGY↗