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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 OSTI2022

Automated defect identification in electroluminescence images of solar modules

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

14 SOLAR ENERGY↗
DOE OSTI2024

Towards Polymer-Free, Femto-Second Laser-Welded Glass/Glass Solar Modules

This project explores the use of femto-second (fs) lasers to form glass-to-glass welds for hermetically sealed, polymer-free solar modules. Low iron solar glass coupons were welded together without the use of glass filler using a fs laser with dedicated optics to elongate the focal plane parallel to the incident beam. The resulting welds were then stress tested to failure to reveal the critical stress intensity factor, KIc. These values were used in a structural mechanics model of a 1 m by 2 m glass/glass module under a simulated static load test. The results show that the fs laser welds are strong enough for a suitably framed module to pass the IEC 61215 static load test with a load of 5400 Pa. Key to this finding is that the module must be framed and braced, and the glass must be ribbed to allow pockets for the cells and welds inside the border of the module. The result is a module design that is completely polymer-free, hermetically sealed, has improved thermal properties, and is easily recycled.

femto-second laser welded↗
DOE OSTI2023

Seed‐Assisted Growth for Scalable and Efficient Perovskite Solar Modules

Perovskite solar modules (PSMs) have shown remarkable photovoltaic potentials, but they still suffer from large power conversion efficiency (PCE) loss on scale‐up and instability due to inferior uniformity and crystallization over large areas. Herein, the scalable production of efficient and stable PSMs using a suite of all‐scalable fabrication methods featuring a two‐step blade/dip‐coating approach to deposit the perovskite absorber layer is demonstrated. Rubidium chloride is introduced to embed (PbI 2 ) 2 RbCl complex seeds in the first‐deposited PbI 2 precursor, which assists in uniform crystallization of the perovskite layer with high crystallinity and reduced defect density over large areas. Following the optimization of RbCl additives, a champion PSM with 17.9% PCE on a 7.6 × 7.6 cm 2 substrate with a 37 cm 2 aperture area is achieved. Moreover, the RbCl‐incorporated PSMs demonstrate excellent reproducibility and stability under continuous 1 sun illumination. This work shows that the two‐step blade/dip coating is a promising method for producing high‐efficiency and stable PSMs on an industrially relevant scale.

Energy & Fuels↗
DOE OSTI2022

Constraining the charge-, time-, and rigidity-dependence of cosmic-ray solar modulation with AMS-02 observations during Solar Cycle 24

Our basic theoretical understanding of the sources of cosmic rays and their propagation through the interstellar medium is hindered by the Sun, that through the solar wind affects the observed cosmic-ray spectra. This effect is known as solar modulation. Recently released cosmic-ray observations from the Alpha Magnetic Spectrometer (AMS-02) and publicly available measurements of the solar wind properties from the Advanced Composition Explorer and the Wilcox observatory allow us to test the analytical modeling of the time-, charge- and rigidity-dependence of solar modulation. We rely on associating measurements on the local heliospheric magnetic field and the heliospheric current sheet’s tilt angle, to model the time-dependence and amplitude of cosmic-ray solar modulation. We find evidence for the solar modulation’s charge- and rigidity-dependence during the era of solar cycle 24. Our analytic prescription to model solar modulation can explain well the large-scale time evolution of positively charged cosmic-ray fluxes in the range of rigidities from 1 GV to 10 GV. Here, we also find that cosmic-ray electron fluxes measured during the first years of cycle 24 are less trivial to explain, due to the complex and rapidly evolving structure of the heliosphere’s magnetic field that they experienced as they propagated inwards.

72 PHYSICS OF ELEMENTARY PARTICLES AND FIELDS↗
DOE OSTI2025

Solar Modulation of Cosmic Nuclei over a Solar Cycle: Results from the Alpha Magnetic Spectrometer

We report the properties of precision time structures of cosmic nuclei He, Li, Be, B, C, N, and O fluxes over an 11-year solar cycle from May 2011 to November 2022 in the rigidity range from 1.92 to 60.3 GV. The nuclei fluxes show similar but not identical time variations with amplitudes decreasing with increasing rigidity. In particular, below 3.64 GV the Li, Be, and B fluxes, and below 2.15 GV the C, N, and O fluxes, are significantly less affected by solar modulation than the He flux. We observe that these differences in solar modulation are linearly correlated with the differences in the spectral indices of the cosmic nuclei fluxes. This shows, in a model-independent way, that solar modulation of galactic cosmic nuclei depends on their spectral shape. In addition, solar modulation differences due to nuclei velocity dependence on the mass-to-charge ratio (𝐴/𝑍) are not observed.

cosmic ray composition & spectra↗
DOE OSTI2021

The Role of Water on the Interfacial Adhesion in Si Solar Modules

Delamination of solar module interfaces often occurs in field-tested solar modules after decades of service due to environmental stressors such as humidity. As water diffuses into the module, failure mechanisms like corrosion and delamination are significantly affected. In the presence of water, the interfaces between EVA and the cell, glass, and backsheet all experience losses of adhesion exposing the module to accelerated degradation. Understanding the relation between interfacial adhesion and water content inside PV modules can help mitigate detrimental power losses. Water content measurements via short wave infrared reflectometry combined with 180 degrees peel tests were used to study and quantify the effect of water ingress and egress on adhesion. Changes in adhesion strength for different module interfaces are quantified, correlating spatial distribution of water content to adhesion for damp heat and dry heat exposed samples. After 1000 hours of damp heat exposure, decreases in adhesion strength of approximately 1 N/mm were noted for all interfaces.

adhesion↗
DOE OSTI2021

Local Resistance Measurement for Degradation of c-Si Heterojunction with Intrinsic Thin Layer (HIT) Solar Modules

Silicon heterojunction with intrinsic thin layer (or HIT) modules typically degrade at a rate of less than 1% annually in solar fields with dominant degradation in open-circuit voltage and some degradation in series resistance. However, detailed mechanisms can differ from module to module. Here, we study increases in local series resistance that occur over long-term field deployment, indicated by cell areas where the photoluminescence intensity does not degrade but the electroluminescence degrades significantly. To directly measure the local series resistance, we have cored out the local electroluminescence-degraded area, and we measured the sheet resistance by 4-point-probe and local nm-scale resistance using scanning spreading resistance microscopy (SSRM). The results by 4-point-probe show scattered sheet resistance that can be caused, for example, by nonuniform current paths through the transparent conductive oxide layer, the a-Si:H emitter, or the near-junction c-Si inversion layer. In contrast, the SSRM results indicate a relatively uniform and non-degraded resistivity on smaller nanometer spatial scales. SSRM is an atomic force microscopy-based two-terminal resistance mapping technique that measures the local resistance in nm-volume beneath the probe. The consistent resistances measured on the control and degraded samples can exclude the degradation of transparent conductive oxide resistance.

41 EE - Solar Energy Technologies Office (EE-4S)↗
NASA NTRS1982

Observations of solar particle propagation and solar modulation

The solar wind provides a unique opportunity for a study of the propagation of energetic particles in irregular magnetic fields on scales which are of astrophysical interest. Problems concerning the conduction of such a study are related to the great number of different factors which affect the motion of the solar particles. Observations related to solar particle propagation are considered, taking into account approaches involving the adjustment of parameters in analytical models to produce fits to the observed time-intensity and time-anisotropy profiles, and new classes of solar particle events, long and short-term modulations of galactic cosmic rays are discussed, giving attention to observations of modulation at high energies, a low energy solar cycle modulation, and mechanisms of modulation.

Mckibben, R. B.↗
NASA NTRS1980

Automated solar module assembly line

The solar module assembly machine which Kulicke and Soffa delivered under this contract is a cell tabbing and stringing machine, and capable of handling a variety of cells and assembling strings up to 4 feet long which then can be placed into a module array up to 2 feet by 4 feet in a series of parallel arrangement, and in a straight or interdigitated array format. The machine cycle is 5 seconds per solar cell. This machine is primarily adapted to 3 inch diameter round cells with two tabs between cells. Pulsed heat is used as the bond technique for solar cell interconnects. The solar module assembly machine unloads solar cells from a cassette, automatically orients them, applies flux and solders interconnect ribbons onto the cells. It then inverts the tabbed cells, connects them into cell strings, and delivers them into a module array format using a track mounted vacuum lance, from which they are taken to test and cleaning benches prior to final encapsulation into finished solar modules. Throughout the machine the solar cell is handled very carefully, and any contact with the collector side of the cell is avoided or minimized.

Bycer, M.↗
NASA NTRS1981

The application of fracture mechanics to failure analysis of photovoltaic solar modules

Cracking of silicon solar cells and solar module transparent cover panels such as glass or polymethylmethacrylate (PMMA) is a major cause of photovoltaic solar module failure in field service. Silicon and cover materials are brittle, and cracking of these materials is expected to result from the extension of preexisting flaws under stress. Study of the cracking mechanisms is therefore an appropriate area for the application of fracture mechanics principles. In this study, fracture mechanics techniques were employed to identify the mode of crack propagation, to examine the fracture-initiating flaw, to estimate the nature and magnitude of fracture stress in the field, and to predict analytically the service lifetime. Recommendations for corrective actions are also made.

Chen, C. P.↗
DOE OSTI2024

A thermotropic liquid crystal enables efficient and stable perovskite solar modules

Perovskite solar cells have seen impressive progress in performance and stability, yet maintaining efficiency while scaling area remains a challenge. Here we find that additives commonly used to passivate large-area perovskite films often co-precipitate during perovskite crystallization and aggregate at interfaces, contributing to defects and to spatial inhomogeneity. Here we develop design criteria for additives to prevent their evaporative precipitation and enable uniform passivation of defects. We explored liquid crystals with melting point below the perovskite processing temperature, functionalization for defect passivation and hydrophobicity to improve device stability. We find that thermotropic liquid crystals such as 3,4,5-trifluoro-4'-(trans-4-propylcyclohexyl)biphenyl enable large-area perovskite films that are uniform, low in defects and stable against environmental stress factors. We demonstrate modules with a certified stabilized efficiency of 21.1% at an aperture area of 31 cm 2 and enhanced stability under damp-heat conditions (ISOS-D-3, 85% relative humidity, 85 °C) with T 86 (the duration for the efficiency to decay to 86% of the initial value) of 1,200 h, and reverse bias with (ISOS-V-1, negative maximum-power-point voltage) and without bypass diodes.

14 SOLAR ENERGY↗
DOE OSTI2022

Row spacing as a controller of solar module temperature and power output in solar farms

We report that when the temperature of solar photovoltaic modules rises, efficiency drops and module degradation accelerates. The spatial arrangement of solar modules can affect convective cooling and, consequently, module temperatures. However, the impact of row spacing on convective cooling in realistic solar farms has not yet been studied. Here, we develop six solar farm arrangements consisting of a fixed number of rows with varying streamwise row spacing. We model the flow and heat transfer of each solar farm using high-resolution large-eddy simulations. Results indicate that increasing row spacing can enhance convective cooling by 14.8%, which reduces module temperature by 6.6 °C and increases power output by 4.0% on average.

14 SOLAR ENERGY↗
DOE OSTI2022

Efficient monolithic all-perovskite tandem solar modules with small cell-to-module derate

All-perovskite tandem solar modules are promising to reduce the cost of photovoltaic systems with their high efficiency and solution fabrication, but their sensitivity to air still imposes a great challenge. Here a hot gas-assisted blading method is developed to accelerate the perovskite solidification, forming compact and thick narrow bandgap (NBG) perovskite films. Adding a reduction agent into NBG films followed by a short period of air exposure and a post-fabrication storage surprisingly increases carrier recombination lifetime and enables laser scribing in ambient conditions without obvious loss of device performance. This combination suppresses tin and iodide oxidation and forms a thin SnO 2 layer on the NBG film surface. Monolithic all-perovskite tandem solar modules showed a champion efficiency of 21.6% with a 14.3 cm 2 aperture area, corresponding to an active area efficiency of 23.0%. Lastly, the very small cell-to-module derate of 6.5% demonstrates the advantage of a tandem monolithic structure for solar modules.

14 SOLAR ENERGY↗
DOE OSTI2024

Analyzing the impact of design factors on solar module thermomechanical durability using interpretable machine learning techniques

Solar modules in utility-scale systems are expected to maintain decades of lifetime to rival conventional energy sources. However, cyclic thermomechanical loading often degrades their long-term performance, highlighting the importance of effective design to mitigate thermal expansion mismatches between module materials. Given the complex composition of solar modules, isolating the impact of individual components on overall durability remains a challenging task. In this work, we analyze a comprehensive data set that comprises bill-of-materials (BOM) and thermal cycling power loss from 251 distinct module designs to identify the predominant design factors and their impacts on the thermomechanical durability of modules. The methodology of our analysis combines machine learning modeling (random forest) and Shapley additive explanation (SHAP) to correlate design factors with power loss and interpret the model’s decision-making. The interpretation reveals that silicon type (monocrystalline or polycrystalline), encapsulant thickness, busbar numbers, and wafer thickness predominantly influence the degradation. With lower power loss of around 0.6% on average in the SHAP analysis, monocrystalline cells present better durability than polycrystalline cells. This finding is further substantiated by statistical testing on our raw data set. The SHAP analysis also demonstrates that while thicker encapsulants lead to reduced power loss, further increasing their thickness over around 0.6 to 0.7 mm does not yield additional benefits, particularly for the front side one. In addition, other important BOM features such as the number of busbars are analyzed. This study provides a blueprint for utilizing explainable machine learning techniques in a complex material system and can potentially guide future research on optimizing the design of solar modules.

14 SOLAR ENERGY↗