Joseph D. Puskar

Accelerated testing of metal foil tape joints and their effect of photovoltaic module reliability

A program is underway at Sandia National Laboratories to predict long-term reliability of photovoltaic (PV) systems. The vehicle for the reliability predictions is a Reliability Block Diagram (RBD), which models system behavior. Because this model is based mainly on field failure and repair times, it can be used to predict current reliability, but it cannot currently be used to accurately predict lifetime. In order to be truly predictive, physics-informed degradation processes and failure mechanisms need to be included in the model. This paper describes accelerated life testing of metal foil tapes used in thin-film PV modules, and how tape joint degradation, a possible failure mode, can be incorporated into the model.

The effect of metal foil tape degradation on the long-term reliability of PV modules

A program is underway at Sandia National Laboratories1 to predict long-term reliability of photovoltaic systems. The vehicle for the reliability predictions is a Reliability Block Diagram (RBD), which models system behavior. Because this model is based mainly on field failure and repair times, it cannot currently be used to accurately predict end-of-life. In order to be truly predictive, physics-informed degradation processes and failure mechanisms need to be included in the model. This paper describes accelerated life testing of metal foil tapes used in thin-film PV modules, and how tape joint degradation, a possible failure mode, can be incorporated into the model.

Experiments and modeling to characterize microstructure and hardness in 304L

Drawn 304L stainless steel tubing was subjected to 42 different annealing heat treatments with the goal of initializing a microstructural model to select a heat treatment to soften the tubing from a hardness of 305 Knoop to 225–275 Knoop. The amount of recrystallization and grain size caused by 18 heat treatments were analyzed via optical microscopy and image analysis, revealing the full range of recrystallization from 0 to 100%. The formation of carbides during the longer duration and higher-temperature heat treatments was monitored via transmission electron microscope evaluation. The experimental results informed a model which includes recovery, recrystallization, and grain growth to predict microstructure and hardness. After initialization of the model, it was able to predict hardness with a R2 value of 0.95 and recrystallization with an R2 value of 0.99. The model was then utilized in the design and testing of a heat treatment to soften the tubing.

Code Case Validation of Impulsively Loaded EDS Subscale Vessel.

The Explosive Destruction System (EDS) was developed by Sandia National Laboratories for the US Army Product Manager for Non-Stockpile Chemical Materiel (PMNSCM) to destroy recovered, explosively configured, chemical munitions. PMNSCM currently has five EDS units that have processed over 850 items. The system uses linear and conical shaped charges to open munitions and attack the burster followed by chemical treatment of the agent. The main component of the EDS is a stainless steel, cylindrical vessel, which contains the explosion and the subsequent chemical treatment. Extensive modeling and testing have been, and continue to be used, to design and qualify the vessel for different applications and conditions. This has included explosive overtests using small, geometrically scaled vessels to study overloads, plastic deformation, and failure limits. Recently the ASME Task Group on Impulsively Loaded Vessels has developed a Code Case under Section VIII Division 3 of the ASME Boiler and Pressure Vessel Code for the design of vessel like the EDS. In this article, a representative EDS subscale vessel is investigated against the ASME Design Codes for vessels subjected to impulsive loads. Topics include strain-based plastic collapse, fatigue and fracture analysis, and leak-before-burst. Vessel design validation is based on model results, where the high explosive (HE) pressure histories and subsequent vessel response (strain histories) are modeled using the analysis codes CTH and LS-DYNA, respectively.Copyright

Selective Galvanizing Using Kinetic Spraying

General corrosion protection of sheet materials such as steel used in automobile construction has reached a high level of performance, due primarily to the incorporation of mill-applied treatments such as electrogalvanizing, galvannealing and other coil-coating processes developed over the last half century. While such treatments have greatly extended the corrosion resistance of steel and its various body constructs, attention is now focused on aspects of the manufacturing process wherein these intended protections are compromised by such features as weldments, joins, cut edges and extreme metal deformations such as hems. A novel metal deposition process, based on high-velocity impact fusion of solid metal particles, has been used to extend the corrosion resistance of base steel and pre-galvanized sheet, by selectively placing highly controlled depositions of zinc and other sacrificial materials in close proximity to critical manufacturing details. The technology of this process is reviewed and preliminary results are reported for hem flange construction.