Arc welding still requires deeper process understanding and more accurateprediction of the heat transferred to the base metal. This can be provided by CFD modelling.Most works done to model arc discharge using CFD consider the arc corealone. Arc core simulation requires applying extrapolated experimental data asboundary conditions on the electrodes. This limits the applicability. To become independent of experimental input the electrodes need to be included in the arcmodel. The most critical part is then the interface layer between the electrodesand the arc core. This interface is complex and non-uniform, with specific physicalphenomena.The present work reviews the concepts of plasma and arc discharges that areuseful for this problem. The main sub-regions of the model are described, andtheir dominant physical roles are discussed.The coupled arc-electrode model is developed in different steps. First couplingsolid and fluid regions for a simpler problem without complex couplinginterface. This is applied to a laser welding problem using the CFD softwareOpenFOAM. The second step is the modelling of the interface layer betweencathode and arc, or cathode layer. Different modelling approaches available inthe literature are studied to determine their advantages and drawbacks. One ofthem developed by Cayla is used and further improved so as to satisfy the basicprinciples of charge and energy conservation in the different regions of thecathode layer. A numerical procedure is presented. The model, implementedin MATLAB, is tested for different arc core and cathode conditions. The maincharacteristics calculated with the interface layer model are in good agreementwith the reference literature. The future step will be the implementation of theinterface layer model in OpenFOAM.

Active layer morphology of polymer-based solar cells plays an important role in improving power conversion efficiency (PCE). In this thesis, the focus is to improve the device efficiency of polymer-based solar cells. In the first objective, active layer morphology of polymer-solar cells was optimized though a novel solvent annealing technique. The second objective was to explore the possibility of replacing the highly sensitive aluminum cathode layer with a low-cost and stable alternative, copper metal. Large scale manufacturing of these solar cells is also explored using roll-to-roll printing techniques. Poly (3-hexylthiophene) (P3HT) and phenyl-C61-butyric acid methyl (PCBM) were used as the active layer blend for fabricating the solar cell devices using bulk heterojunction (BHJ), which is a blend of a donor polymer and an acceptor material. Blends of the donor polymer, P3HT and acceptor, PCBM were cast using spin coating and the resulting active layers were solvent annealed with dichlorobenzene in an inert atmosphere. Solvent annealed devices showed improved morphology with nano-phase segregation revealed by atomic force microscopy (AFM) analysis. The roughness of the active layer was found to be 6.5 nm. The nano-phase segregation was attributed to PCBM clusters and P3HT domains being arranged under the solvent annealing conditions. These test devices showed PCE up to 9.2 % with current density of 32.32 mA/cm2, which is the highest PCE reported to date for a P3HT-PCBM based system. Copper was deposited instead of the traditional aluminum for device fabrication. We were able to achieve similar PCEs with copper-based devices. Conductivity measurements were done on thermally deposited copper films using the two-probe method. Further, for these two configurations, PCE and other photovoltaic parameters were compared. Finally, we studied new techniques of large scale fabrication such as ultrasonic spray coating, screen-printing, and intense pulse light sintering, using the facilities at the Conn Center for Renewable Energy Research at the University of Louisville. In this study, prototype devices were fabricated on flexible ITO coated plastics. Sintering greatly improved the conductivity of the copper nano-ink cathode layer. We will explore this technique’s application to large-scale fabrication of solar cell devices in the future work.