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Polycrystalline silicon (pc-Si, grain size > 1??m, no amorphous tissue) on glass is an interesting material for thin-film solar cells due to the low costs, the abundance and the non-toxic character of Si, and the properties of pc-Si like long-term stability and lateral conductance. Glass as supporting material significantly complicates the fabrication process as it limits the thermal budget and the maximum temperature. In this work, the feasibility of forming large-grained pc-Si thin-film solar cells on glass by ion-assisted deposition (IAD) on aluminium-induced crystallisation (AIC) seed layers (ALICIA solar cells) is investigated. IAD allows epitaxial growth at high rate, and being based on evaporation, is of low cost (high source material usage, no toxic gases involved). High-quality epitaxy on (100)-oriented Si wafer substrates is demonstrated in a non{UHV environment, to further increase its industrial appli- cability. High{rate growth and a sacrificial protective layer control contamination problems associated with the non-UHV environment. The process is then trans- ferred to AIC-seeded glass and optimised, with particular focus on the influence of the glass. Using high-temperature rapid thermal annealing and hydrogenation as post-deposition treatments, ALICIA solar cells with a 1-Sun open-circuit voltage of 420 mV are achieved. Moreover, two novel characterisation techniques are presented. One allows the fast and non-destructive assessment of the structural quality of pc-Si films using opti- cal measurements. Furthermore, `impedance analysis', a novel capacitance-voltage measurement technique based on impedance spectroscopy, is presented. It allows the reliable determination of the absorber layer doping density and the built{in potential of non-ideal p-n junction solar cells. The latter is used to investigate the influence of post{deposition treatments on the n-type absorber layer doping of ALICIA solar cells. It is found, using temperature dependent impedance analysis, that unintentional doping and defects have a strong influence on the absorber layer doping. A maximum in the short-circuit current density of ALICIA solar cells is found for phosphorus concentrations in the absorber of 1??1017 cm??3. For such ALI- CIA cells a base difusion length in the range 600 - 950nm, a short{circuit current density in the range 10 - 13.5 mA/cm2 and an energy conversion efficiency of 2.2% are obtained.

This thesis work demonstrates the feasibility to fabricate high-efficiency crystalline silicon solar cells by using metal stencil printing technique to replace screen printing or electroless plating techniques for implementing crystalline silicon solar cell front metallization. The developed laser-cut stainless steel stencils successfully challenge two of the cell performance limitations associated with commercial screen printing technology: the wide and non-uniform front gridline fingers and low height-to-width aspect ratio of the fingers. These limitations lower the short circuit current density, the fill factor and, in turn, the efficiency of a screen printed solar cell. Metal stencils are capable of printing fine, high and continuous features on the cell front that have a high aspect ratio. Both single-level and double-level structured stainless steel stencils for solar cell front metallization have been developed, with laser-cut double-level stainless steel stencils being demonstrated for the first time worldwide. Both of them are able to print fine, high and continuous gridline pattern to the front surfaces of solar cells in one step, with a certain number of special short bridges being put at the places where fingers meet busbar and along fingers and busbar. The deformation issue of the very thin stainless steel foils due to its thermal expansion in the process of laser cutting is solved by increasing the energy content in each laser pulse that impinges upon the stainless steel foil with changed Q-switch frequencies, while maintaining the laser average output energy in unit time to an optimum value. A chemical etching process has been developed to etch the dross that results from laser cutting, resulting in well formed metal stencils suitable for printing. By a comparison between the metal stencil printed and conventional mesh screen printed silicon solar cells, which are fabricated on similar Cz silicon wafers with a almost identical cell processing sequence except for using different front contact printing masks, the following conclusions are reached: Fired Ag finger lines with 75-??m width on finished solar cells, using a doublelevel stainless steel stencil can be achieved. In contrast, the fired Ag finger line on finished solar cells using a traditional mesh screen is 121-??m wide. The stencil printed finger is smoother and more uniform than by screen printing and the former has a 25-??m fired finger height with a 0.33 height-to-width aspect ratio, compared to a 10-??m fired finger height with a 0.08 height-to-width aspect ratio for the later. With these advantages, the 4-cm2 stencil-printed silicon solar cells has an averaged 1.28 mA/cm2 higher short circuit current and an averaged 5.9% higher efficiency than the 4-cm2 screen printed silicon solar cell, which identifies one of the key advantages of solar cell metallization schemes by using metal stencil printing in place of screen printing. Using a ???feedback alignment??? method for registration of the laser-formed metal stencil printed pattern and the laser-formed groove pattern, Ag paste can be printed and filled into wafer grooves by using a hand-operated without an optical vision system. The fired finger profile is 50-??m wide and 22-??m high. The best metal stencil printed, selective emitter silicon solar cell demonstrates a 34.2 mA/cm2 short circuit current density, 625 mV open circuit voltage, 0.77 fill factor and 16.4% efficiency, with an excellent spectral response at short wavelengths due to its selective emitter cell structure. It is believed that the performance of this type of solar cell can be enhanced with a screen printer that has an optical vision system and an automatic alignment device. The successful development of metal stencil printed silicon solar cells demonstrates the feasibility of the metal stencil printing as a beneficial technology for the PV industry.

Using electron beam evaporation for the production of polycrystalline silicon (pc-Si) thin-film solar cells is an attractive alternative to PECVD deposition. Due to its faster deposition rate, using evaporation technology could significantly reduce module production costs. Other advantages are lower running costs, and the fact that no toxic gases are involved. However, currently no on-shelf equipment is available, and research in this field often relies on in-house designed systems. These can have various problems with reliability, deposition uniformity, and due to their custom design require frequent maintenance. In this work, a newly purchased electron beam evaporation system was upgraded and redesigned to be capable of depositing amorphous Si diodes for the fabrication of pc-Si thin-film solar cells. The main goal of the upgrade was to provide a safe and reliable tool which allows for the deposition of high purity semiconductor material. Reliable and safe operation was accomplished by designing the entire electrical supply circuit and incorporating various safety interlocks. Source cross-contamination issues were addressed by installing a specially designed shroud (source housing). To provide uniform substrate temperatures up to 600??C, a heater was specially designed, fabricated, installed and tested. Accurate design of all mechanical system components was realised by using 3D product design software (ProEngineer). The new evaporator was commissioned, which included testing and calibration of all the system components required for depositing on substrate sizes of up to 10x10cm2. Over this area a Si film thickness uniformity of +/-2%, performed with a maximum deposition rate of 7nm/s was achieved. Initial experiments using solid phase crystallisation and rapid thermal annealing revealed a sheet resistance uniformity of +/-4% for the Phosphorus and +/-7% for the Boron dopant effusion cell. Experimentation via Raman spectrometry and X-ray diffraction has revealed good crystalline properties, of the crystallised Si films, which is comparable to those of existing evaporation systems. Although the system was upgraded to achieve deposition pressures below 3x10-7 mbar, experiments have shown that this quality of vacuum may not be necessary for the fabrication of low impurity films. The system is now ready for further research in the field of thin-film photovoltaics, and the first functioning devices have been fabricated.

The cost of photovoltaic electricity needs to be significantly reduced in order to achieve a high electricity market penetration. Thin-film solar cells have good potential to achieve such cost savings though (i) large-area deposition onto low-cost foreign substrates, (ii) more streamlined processing, (iii) monolithic cell interconnection, and very efficient use of the expensive semiconductor material. Polycrystalline silicon (poly-Si) on glass is a promising technology for the cost-effective large volume production of PV modules since it (i) makes use of an abundant raw material, (ii) is non-toxic, (iii) does not suffer from light-induced degradation, and (iv) does not rely on TCO layers. Usually plasma enhanced chemical vapour deposition (PECVD) is used for the layer formation. This thesis explores the use of e-beam evaporation as deposition method since it is potentially much faster and cheaper than PECVD. The resulting solar cells are referred to as EVA (from EVAporation). Two inherent shunting mechanisms in EVA cells are demonstrated to be shunting through sub-micron sized pinholes when the back electrode is deposited and shunting between the emitter and the absorber layer at the glass-side electrode. Through the improved understanding of these shunting mechanisms it was possible to develop a suitable metallisation scheme for EVA cells using an aligned deposition of emitter and back surface field line contacts and a specially developed shunt mitigation etching technique. For the first time appreciable efficiencies of up to 5.2% were demonstrated on this material. It was also shown that only very lightly doped absorber layers can lead to the required high short-circuit currents in EVA cells. The resulting cells are currently completely limited by space charge region recombination occurring with comparatively low ideality factors of only ~ 1.4 This thesis also demonstrates the usefulness of Jsc-Suns measurements and investigates optical loss mechanisms in the current devices. Advanced modelling of distributed series resistance effects, influencing Suns-Voc, m-Voc and Jsc-Suns curves, is employed. PC1D modelling is used to extract relevant device parameters. In this work it was found that the diffusion length in the best EVA cells is longer than the absorber layer and that insufficient light trapping is currently the major hurdle to higher cell efficiencies. From the obtained results it can be concluded that EVA solar cells are promising candidates for the low-cost and high-volume production of solar modules.

Aluminium composites reinforced by particles have received considerable attention because of their superior mechanical properties over monolithic aluminum matrix. Over the last ten years, nanocomposites with nano-sized reinforcements have become a revolutionary progress for composites because they have different strengthening mechanisms as compared to that in composites with micro-sized reinforcements. Consequently novel properties can be expected from the nanometric particulate reinforced composites. The aim of this project was to fabricate SiC (50nm)/7075 aluminium composites via a modified powder metallurgy and extrusion route. Ageing treatment was used to increase the strength of the composites and mechanical tests, including tensile test and abrasive wear test, were performed. The effects of nanometric silicon carbide particulates to the ageing behaviours and mechanical properties of the composites have been studied by optical metallography, scanning electron microscopy and transmission electron microscopy. It was found that the dispersion of nanometric silicon carbide was not homogeneous, but tended to disperse along grain boundaries. Clustering of these nano-reinforcements was also found within the grains. This was particular true when the amount of nano-reinforcement increased to 5%. Compared with the monolithic 7075 alloy, the 1 vol.% SiC (50nm)/7075 aluminium had a higher strength because of effective dislocation pinnings by the reinforcements, while 5% SiC (50nm)/7075 had a much lower strength and ductility because of severe aggregation of nanometric particulates. Nanometric silicon carbide was not as effective as the micro ones in improving abrasive wear resistance of aluminium, this was because of micro-cracking in the aggregation and relatively large abrasive grit. In summary, the addition of a small amount of SiC nanoreinforcements has a high potential to further strengthen 7xxx aluminium alloy. However, the clustering of reinforcements in the matrix will detrimentally affect the strength and ductility of the alloy. The wear resistance of nanometric particulate reinforced composites was inferior to those with micrometric reinforcements. It is suggested that by improving the dispersion of nanometric reinforcements, as well as putting in reinforcememts with different sizes, the mechanical properties and wear resistance can both be increased.

This thesis work demonstrates the feasibility to fabricate high-efficiency crystalline silicon solar cells by using metal stencil printing technique to replace screen printing or electroless plating techniques for implementing crystalline silicon solar cell front metallization. The developed laser-cut stainless steel stencils successfully challenge two of the cell performance limitations associated with commercial screen printing technology: the wide and non-uniform front gridline fingers and low height-to-width aspect ratio of the fingers. These limitations lower the short circuit current density, the fill factor and, in turn, the efficiency of a screen printed solar cell. Metal stencils are capable of printing fine, high and continuous features on the cell front that have a high aspect ratio. Both single-level and double-level structured stainless steel stencils for solar cell front metallization have been developed, with laser-cut double-level stainless steel stencils being demonstrated for the first time worldwide. Both of them are able to print fine, high and continuous gridline pattern to the front surfaces of solar cells in one step, with a certain number of special short bridges being put at the places where fingers meet busbar and along fingers and busbar. The deformation issue of the very thin stainless steel foils due to its thermal expansion in the process of laser cutting is solved by increasing the energy content in each laser pulse that impinges upon the stainless steel foil with changed Q-switch frequencies, while maintaining the laser average output energy in unit time to an optimum value. A chemical etching process has been developed to etch the dross that results from laser cutting, resulting in well formed metal stencils suitable for printing. By a comparison between the metal stencil printed and conventional mesh screen printed silicon solar cells, which are fabricated on similar Cz silicon wafers with a almost identical cell processing sequence except for using different front contact printing masks, the following conclusions are reached: Fired Ag finger lines with 75-??m width on finished solar cells, using a doublelevel stainless steel stencil can be achieved. In contrast, the fired Ag finger line on finished solar cells using a traditional mesh screen is 121-??m wide. The stencil printed finger is smoother and more uniform than by screen printing and the former has a 25-??m fired finger height with a 0.33 height-to-width aspect ratio, compared to a 10-??m fired finger height with a 0.08 height-to-width aspect ratio for the later. With these advantages, the 4-cm2 stencil-printed silicon solar cells has an averaged 1.28 mA/cm2 higher short circuit current and an averaged 5.9% higher efficiency than the 4-cm2 screen printed silicon solar cell, which identifies one of the key advantages of solar cell metallization schemes by using metal stencil printing in place of screen printing. Using a ???feedback alignment??? method for registration of the laser-formed metal stencil printed pattern and the laser-formed groove pattern, Ag paste can be printed and filled into wafer grooves by using a hand-operated without an optical vision system. The fired finger profile is 50-??m wide and 22-??m high. The best metal stencil printed, selective emitter silicon solar cell demonstrates a 34.2 mA/cm2 short circuit current density, 625 mV open circuit voltage, 0.77 fill factor and 16.4% efficiency, with an excellent spectral response at short wavelengths due to its selective emitter cell structure. It is believed that the performance of this type of solar cell can be enhanced with a screen printer that has an optical vision system and an automatic alignment device. The successful development of metal stencil printed silicon solar cells demonstrates the feasibility of the metal stencil printing as a beneficial technology for the PV industry.

This thesis work demonstrates the feasibility to fabricate high-efficiency crystalline silicon solar cells by using metal stencil printing technique to replace screen printing or electroless plating techniques for implementing crystalline silicon solar cell front metallization. The developed laser-cut stainless steel stencils successfully challenge two of the cell performance limitations associated with commercial screen printing technology: the wide and non-uniform front gridline fingers and low height-to-width aspect ratio of the fingers. These limitations lower the short circuit current density, the fill factor and, in turn, the efficiency of a screen printed solar cell. Metal stencils are capable of printing fine, high and continuous features on the cell front that have a high aspect ratio. Both single-level and double-level structured stainless steel stencils for solar cell front metallization have been developed, with laser-cut double-level stainless steel stencils being demonstrated for the first time worldwide. Both of them are able to print fine, high and continuous gridline pattern to the front surfaces of solar cells in one step, with a certain number of special short bridges being put at the places where fingers meet busbar and along fingers and busbar. The deformation issue of the very thin stainless steel foils due to its thermal expansion in the process of laser cutting is solved by increasing the energy content in each laser pulse that impinges upon the stainless steel foil with changed Q-switch frequencies, while maintaining the laser average output energy in unit time to an optimum value. A chemical etching process has been developed to etch the dross that results from laser cutting, resulting in well formed metal stencils suitable for printing. By a comparison between the metal stencil printed and conventional mesh screen printed silicon solar cells, which are fabricated on similar Cz silicon wafers with a almost identical cell processing sequence except for using different front contact printing masks, the following conclusions are reached: Fired Ag finger lines with 75-??m width on finished solar cells, using a doublelevel stainless steel stencil can be achieved. In contrast, the fired Ag finger line on finished solar cells using a traditional mesh screen is 121-??m wide. The stencil printed finger is smoother and more uniform than by screen printing and the former has a 25-??m fired finger height with a 0.33 height-to-width aspect ratio, compared to a 10-??m fired finger height with a 0.08 height-to-width aspect ratio for the later. With these advantages, the 4-cm2 stencil-printed silicon solar cells has an averaged 1.28 mA/cm2 higher short circuit current and an averaged 5.9% higher efficiency than the 4-cm2 screen printed silicon solar cell, which identifies one of the key advantages of solar cell metallization schemes by using metal stencil printing in place of screen printing. Using a ???feedback alignment??? method for registration of the laser-formed metal stencil printed pattern and the laser-formed groove pattern, Ag paste can be printed and filled into wafer grooves by using a hand-operated without an optical vision system. The fired finger profile is 50-??m wide and 22-??m high. The best metal stencil printed, selective emitter silicon solar cell demonstrates a 34.2 mA/cm2 short circuit current density, 625 mV open circuit voltage, 0.77 fill factor and 16.4% efficiency, with an excellent spectral response at short wavelengths due to its selective emitter cell structure. It is believed that the performance of this type of solar cell can be enhanced with a screen printer that has an optical vision system and an automatic alignment device. The successful development of metal stencil printed silicon solar cells demonstrates the feasibility of the metal stencil printing as a beneficial technology for the PV industry.

<p>The performance of negative electrodes based on Si nanoparticles for Li-ion batteries has been investigated. Electrodes consisted of Si nanoparticles, carbon black and Na-CMC. The investigation covered electrode production parameters such as pre-treatment of the Si-powder, different emulsifiers and cycling with two different electrolytes. Testing of the electrodes’ performance was done electrochemically with two different galvanostatic approaches: constant charge rate and stepped-up charge rate. Electrodes’ morphology, stability and surface chemistry were also evaluated by scanning electron microscopy (SEM), differential scanning calorimetry (DSC), thickness measurements and X-ray photoelectron spectroscopy (XPS).</p><p> </p><p>High electrode capacities were achieved though strong variation depending on electrode thickness has been found. For the best performing electrodes the capacity exceeded 1600 mAh/g with slight fading after 10-15 cycles. The difference in performance could not be assigned to the different production parameters, but had a clear correlation to the thickness of the electrode and the different electrolytes used. Propylene carbonate based electrolyte gives a lower coulombic efficiency and lower capacity retention than an ethylene carbonate-diethyl carbonate based electrolyte. The electrodes could not store any capacity at cycling rates higher than 2C, but were not damaged by cycling rates up to 50C. SEM micrographs revealed that a solid electrolyte interface (SEI) was formed on the electrodes during cycling and their surface analysis by XPS suggested that the SEI was formed by decomposition of electrolyte components.</p>