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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
NASA NTRS1982

Photovoltaic array reliability optimization

An overview of the photovoltaic array reliability problem is presented, and a high reliability/minimum cost approach to this problem is presented. Design areas covered are cell failure, interconnect fatigue, and electrical insulation breakdown, and three solution strategies are discussed. The first involves controlling component failures in the solar cell (cell cracking, cell interconnects) and at the module level (must be statistically treated). Second, a fault tolerant circuit is designed which reduces array degradation, improves module yield losses, and controls hot-spot heating. Third, cost optimum module replacement strategies are also effective in reducing array degradation. This can be achieved by minimizing the life-cycle energy cost of the photovoltaic system. The integration of these solutions is aimed at reducing the 0.01% failure rate.

Ross, R. G., Jr.↗
NASA NTRS1978

Block 2 solar cell module environmental test program

Environmental tests were performed of on 76 solar cell modules produced by four different manufacturers. The following tests were performed: (1) 28 day temperature and humidity; (2) rain and icing; (3) salt fog; (4) sand and dust; (5) vacuum/steam/pressure; (6) fungus; (7) temperature/altitude; and (8) thermal shock. Environmental testing of the solar cell modules produced cracked cells, cracked encapsulant and encapsulant delaminations on various modules. In addition, there was some minor cell and frame corrosion.

Holloway, K. L.↗
NASA NTRS2004

The Rossi X-Ray Timing Explorer (XTE) Solar Array Anomaly

The XTE was launched December 30, 1995. Shortly after launch, it become apparent that the solar array was not performing as expected. On leaving shadow, the array exhibited many discontinuous drops in current output. The size of each of these drops was consistent with the loss of a part of a sell. The current decreases could not be caused by the loss of an entire circuit. This meant that the array may have had numerous cracked solar cells that opened as array got warmer. Studies performed on the array's qualification panel suggest that the cell cracks may have been cased by extensive tap testing performed on the array and that these cracks were undetectable at room temperature using usual inspection method.

Gaddy, Edward M.↗
NASA NTRS1980

An improved lamination technique for solar arrays

Encapsulating solar cells by lamination has been plagued with problems such as bubbles, cell shifting, ripples, and cracked cells. A low-cost laminating procedure has been developed using a double vacuum bagging technique and recently improved formulations of ethylene vinyl acetate, successfully minimizing these problems. The lamination fixturing used is described. The causes and cures of various problems are discussed and solutions to these problems presented. The apparent modulus of the face sheet seen by the module being laminated is believed to be the primary variable which must be optimized. Conditions at the module edge are also considered to be important for producing an acceptable product.

Garcia, A., III↗
NASA NTRS1986

Reliability of photovoltaic modules

In order to assess the reliability of photovoltaic modules, four categories of known array failure and degradation mechanisms are discussed, and target reliability allocations have been developed within each category based on the available technology and the life-cycle-cost requirements of future large-scale terrestrial applications. Cell-level failure mechanisms associated with open-circuiting or short-circuiting of individual solar cells generally arise from cell cracking or the fatigue of cell-to-cell interconnects. Power degradation mechanisms considered include gradual power loss in cells, light-induced effects, and module optical degradation. Module-level failure mechanisms and life-limiting wear-out mechanisms are also explored.

Ross, R. G., Jr.↗
NASA NTRS1982

Investigating reliability attributes of silicon photovoltaic cells - An overview

Reliability attributes are being developed on a wide variety of advanced single-crystal silicon solar cells. Two separate investigations: cell-contact integrity (metal-to-silicon adherence), and cracked cells identified with fracture-strength-reducing flaws are discussed. In the cell-contact-integrity investigation, analysis of contact pull-strength data shows that cell types made with different metallization technologies, i.e., vacuum, plated, screen-printed and soldered, have appreciably different reliability attributes. In the second investigation, fracture strength was measured using Czochralski wafers and cells taken at various stages of processing and differences were noted. Fracture strength, which is believed to be governed by flaws introduced during wafer sawing, was observed to improve (increase) after chemical polishing and other process steps that tend to remove surface and edge flaws.

Royal, E. L.↗
NASA NTRS1985

Fracture strength of GaAs solar cells as a function of manufacturing process steps

Fracture of single crystal GaAs substrate during the solar cell processing is an important factor in solar cell yield and cost. Fracture mechanics technique was utilized to evaluate cell cracking characteristics and changes in fracture strength of GaAs solar cells in a present state-of-the-art of manufacturing process for GaAs solar cells from wafer to complete cell of a typical production line. Considerable change in the fracture strength of GaAs solar cells as a function of cell processing was found. The strength data were described by Weibull statistical analysis and can be interpreted with the change of flaw distribution of each of the manufacturing process steps.

Chen, C. P.↗
NASA NTRS1979

Solar Cell Modules with Parallel Oriented Interconnections

Twenty-four solar modules, half of which were 48 cells in an all-series electrical configuration and half of a six parallel cells by eight series cells were provided. Upon delivery of environmentally tested modules, low power outputs were discovered. These low power modules were determined to have cracked cells which were thought to cause the low output power. The cracks tended to be linear or circular which were caused by different stressing mechanisms. These stressing mechanisms were fully explored. Efforts were undertaken to determine the causes of cell fracture. This resulted in module design and process modifications. The design and process changes were subsequently implemented in production.

Source record↗
NASA NTRS2017

Environmental Barrier Coating Fracture, Fatigue and High-Heat-Flux Durability Modeling and Stochastic Progressive Damage Simulation

Advanced environmental barrier coatings will play an increasingly important role in future gas turbine engines because of their ability to protect emerging light-weight SiC/SiC ceramic matrix composite (CMC) engine components, further raising engine operating temperatures and performance. Because the environmental barrier coating systems are critical to the performance, reliability and durability of these hot-section ceramic engine components, a prime-reliant coating system along with established life design methodology are required for the hot-section ceramic component insertion into engine service. In this paper, we have first summarized some observations of high temperature, high-heat-flux environmental degradation and failure mechanisms of environmental barrier coating systems in laboratory simulated engine environment tests. In particular, the coating surface cracking morphologies and associated subsequent delamination mechanisms under the engine level high-heat-flux, combustion steam, and mechanical creep and fatigue loading conditions will be discussed. The EBC compostion and archtechture improvements based on advanced high heat flux environmental testing, and the modeling advances based on the integrated Finite Element Analysis Micromechanics Analysis Code/Ceramics Analysis and Reliability Evaluation of Structures (FEAMAC/CARES) program will also be highlighted. The stochastic progressive damage simulation successfully predicts mud flat damage pattern in EBCs on coated 3-D specimens, and a 2-D model of through-the-thickness cross-section. A 2-parameter Weibull distribution was assumed in characterizing the coating layer stochastic strength response and the formation of damage was therefore modeled. The damage initiation and coalescence into progressively smaller mudflat crack cells was demonstrated. A coating life prediction framework may be realized by examining the surface crack initiation and delamination propagation in conjunction with environmental degradation under high-heat-flux and environment load test conditions.

Mechanical creep and fatigue loading condition↗
NASA NTRS1996

TRMM Solar Array

Basic requirement of 978.59 watts per Panel output @ 58.9 volts B.O.L. was met on an average basis per agreement with NASA. Lower grade Cells were used on the shadowed Panel (Boom shadow) to maximize available power to the Spacecraft. The average output @ 58.9 volts was 991 watts. The outputs of the four t4) Panels ranged from 960 to 1,022 watts. The Panels successfully passed environmental testing at TRW to the contract specification and subsequent testing at NASA which involved output measurements at elevated temperatures. As this type of Array had never previously been built by TRW (aluminum Substrate with 4 cm x 4.4 cm GaAs Cells), the TRMM Program was a development effort combined with a Qual and Flight production effort. The most significant technical problem was Cell cracking during Qual thermal cycling. The cracking problem was determined to be generic within our Solar Array factory in the application of GaAs Cells to our designs. As a result, a TRW funded manufacturing process verification panel (known as the Manufacturing Verification Panel) was built to demonstrate our ability to properly apply GaAs Cells. The original Qual Panel comprised three (3) design variations with respect to Coverglass-to-Cell and Cell-to-Substrate adhesives. The intent was to qualify multiple designs in case one or more failed. When two of the three combinations failed due to excessive Cell breakage during thermal cycling, NASA was reluctant to allow Flight production based on the one remaining good Qual Panel Quadrant. This issue was pivotal for continuing the contract. Facts and recommendations are as follows: (1) The cause of the excessive cracking was never determined. and (2) The areas where the excessive cracking occurred utilized DC93-500 glassing adhesive which was NASA approved, and had been widely used by TRW on a multitude of projects.

Source record↗
NASA NTRS1980

LSA field test

After almost four years of endurance testing of photovoltaic modules, no fundamental life-limiting mechanisms were identified that could prevent the twenty-year life goal from being met. The endure data show a continual decline in the failure rate with each new large-scale procurement. Cracked cells and broken interconnects continue to be the principal causes of failure. Although the modules are more adversely affected physically by hot, humid environments than by cool or dry environments there are insufficient data to correlate failure with environment. There is little connection between the outward physical condition of a module and changes in its electrical performance.

Jaffe, P.↗
NASA NTRS1982

Photovoltaic module reliability improvement through application testing and failure analysis

During the first four years of the U.S. Department of Energy (DOE) National Photovoltatic Program, the Jet Propulsion Laboratory Low-Cost Solar Array (LSA) Project purchased about 400 kW of photovoltaic modules for test and experiments. In order to identify, report, and analyze test and operational problems with the Block Procurement modules, a problem/failure reporting and analysis system was implemented by the LSA Project with the main purpose of providing manufacturers with feedback from test and field experience needed for the improvement of product performance and reliability. A description of the more significant types of failures is presented, taking into account interconnects, cracked cells, dielectric breakdown, delamination, and corrosion. Current design practices and reliability evaluations are also discussed. The conducted evaluation indicates that current module designs incorporate damage-resistant and fault-tolerant features which address field failure mechanisms observed to date.

Dumas, L. N.↗
NASA NTRS1981

Photovoltaic module hot spot durability design and test methods

As part of the Jet Propulsion Laboratory's Low-Cost Solar Array Project, the susceptibility of fat-plate modules to hot-spot problems is investigated. Hot-spot problems arise in modules when the cells become back-biased and operate in the negative-voltage quadrant, as a result of short-circuit current mismatch, cell cracking or shadowing. The details of a qualification test for determining the capability of modules of surviving field hot-spot problems and typical results of this test are presented. In addition, recommended circuit-design techniques for improving the module and array reliability with respect to hot-spot problems are presented.

Arnett, J. C.↗
NASA NTRS1992

Operational considerations of the Advanced Photovoltaic Solar Array

Issues affecting the long-term operational performance of the Advanced Photovoltaic Solar Array (APSA) are discussed, with particular attention given to circuit electrical integrity from shadowed and cracked cell modules. The successful integration of individual advanced array components provides a doubling of array specific performance from the previous NASA-developed advanced array (SAFE). Flight test modules both recently fabricated and under fabrication are described. The development of advanced high-performance blanket technology for future APSA enhancement is presented.

Stella, Paul M.↗
NASA NTRS2014

Low-Cost, Class D Testing of Spacecraft Photovoltaic Systems Can Reduce Risk

The end-to-end verification of a spacecraft photovoltaic power generation system requires light! Specifically, the standard practice for doing so is the Large Area Pulsed Solar Simulation (LAPSS). A LAPSS test can characterize a photovoltaic system's efficiency via its response to rapidly applied impulses of simulated sunlight. However, a Class D program on a constrained budget and schedule may not have the resources to ship an entire satellite for a LAPSS test alone. Such was the case with the Lunar Atmospheric and Dust Environment Explorer (LADEE) program, which was also averse to the risk of hardware damage during shipment. When the Electrical Power System (EPS) team was denied a spacecraft-level LAPSS test, the lack of an end-to-end power generation test elevated to a project-level technical risk. The team pulled together very limited resources to not only eliminate the risk, but build a process to monitor the health of the system through mission operations. We discuss a process for performing a low-cost, end-to-end test of the LADEE photovoltaic system. The approach combines system-level functional test, panel-level performance results, and periodic inspection (and repair) up until launch. Following launch, mission operations tools are utilized to assess system performance based on a scant amount of data. The process starts in manufacturing at the subcontractor. The panel manufacturer provides functional test and LAPSS data on each individual panel. We apply an initial assumption that the per-panel performance is sufficient to meet the power generation requirements. The manufacturer's data is also carried as the performance allocation for each panel during EPS system modeling and initial mission operations. During integration and test, a high-power, professional theater lamp system provides simulated sunlight to each panel on the spacecraft, thereby permitting a true end-to-end system test. A passing test results in a step response to nearly full-rated current at the appropriate solar array switch in the power system. A metal-halide bulb, infrared imagers, and onboard spacecraft measurements are utilized to minimize risk of thermal damage during test. Data is provided to support test results for both passing and marginal panels. Prior to encapsulation in the launch vehicle, each panel is inspected for damage by the panel manufacturer. Cracked cells or other damage is amended on-site. Because the photovoltaic test system is inexpensive and portable, each repaired panel can be re-verified immediately. Post-launch, the photovoltaic system is again characterized for per-panel deviations from the manufacturer's performance test. This proved especially tricky as the LADEE spacecraft performs only one current measurement on the entire array. The algorithm for Matlab tools to assess panel performance based on spacecraft attitude is discussed. While not as precise and comprehensive as LAPSS, the LADEE approach leverages minimal resources into an ongoing assessment program that can be applied through numerous stages of the mission. The project takes a true Class D approach in assessing the technical value of a spacecraft level performance test versus the programmatic risk of shipping the spacecraft to another facility. The resources required are a fraction of that for a LAPSS test, and is easy to repeat. Further, the test equipment can be handed down to future projects without building an on-site facility.

photovoltaic↗
NASA NTRSDate not supplied

Martian Dust Abrasion Damage on Solar Arrays: HALT Experimental Investigation and Opportunity Rover Performance Analysis

We explored the utility of ground-based highly accelerated life testing (HALT) on epitaxial lift-off (ELO) triple-junction coverglass interconnected cells (CICs) after exposure to simulated Martian dust storms. Dust storm impingement was replicated by sandblasting CICs with Mars dust simulant replicating conditions similar to the weather conditions reported by the Viking landers. We observed that even in cases when there are no observable open circuit voltage (VOC) losses, the minority carrier lifetime is reduced. Short circuit current (JSC) losses can be recovered upon cleaning, suggesting JSC losses are not linked to permanent damage, like cell cracking. This suggests a permanent degradation could be determined by quantifying the difference between recoverable and non-recoverable power loss. We mined field data from the Mars Exploration Rover, Opportunity and extracted a degradation rate to compare to our experimental data. We found exceptional agreement between 4.9 Martian years of mined field data (9.4%) and the irreversible damage observed in our HALT experiment (9.7%). We demonstrate that the laboratory method for exposing CICs to Martian dust storm conditions well represents the physical reality of long duration CIC operation on Mars.

Lyndsey McMillon-Brown↗
NASA NTRS1988

Analytical determination of critical crack size in solar cells

Although solar cells usually have chips and cracks, no material specifications concerning the allowable crack size on solar cells are available for quality assurance and engineering design usage. Any material specifications that the cell manufacturers use were developed for cosmetic reasons that have no technical basis. Therefore, the Applied Solar Energy Corporation (ASEC) has sponsored a continuing program for the fracture mechanics evaluation of GaAs. Fracture mechanics concepts were utilized to develop an analytical model that can predict the critical crack size of solar cells. This model indicates that the edge cracks of a solar cell are more critical than its surface cracks. In addition, the model suggests that the material specifications on the allowable crack size used for Si solar cells should not be applied to GaAs solar cells. The analytical model was applied to Si and GaAs solar cells, but it would also be applicable to the semiconductor wafers of other materials, such as a GaAs thin film on a Ge substrate, using appropriate input data.

Chen, C. P.↗