Failure mechanism of parallel gap resistance welding joint between Ag foil and GaAs solar cell by temperature cycling

Yuhan Ding; Xiaoran Li; Chen Shen; Ye Huang; Yi Wei; Nannan Chen; Min Wang; Lin Wang; Xunchun Wang; Yan Cai; Bin Qian; Xueming Hua

Journal of Materials Research and Technology (Sep 2023)

Failure mechanism of parallel gap resistance welding joint between Ag foil and GaAs solar cell by temperature cycling

Yuhan Ding,
Xiaoran Li,
Chen Shen,
Ye Huang,
Yi Wei,
Nannan Chen,
Min Wang,
Lin Wang,
Xunchun Wang,
Yan Cai,
Bin Qian,
Xueming Hua

Affiliations

Yuhan Ding: Shanghai Key Lab of Materials Laser Processing and Modification, School of Materials Science and Engineering, Shanghai Jiao Tong University, Shanghai 200240, China
Xiaoran Li: Shanghai Institute of Space Power Sources, Shanghai 200245, China
Chen Shen: Shanghai Key Lab of Materials Laser Processing and Modification, School of Materials Science and Engineering, Shanghai Jiao Tong University, Shanghai 200240, China; Corresponding author.
Ye Huang: School of Advanced Manufacturing, Fuzhou University, Jinjiang 362200, China
Yi Wei: Shanghai Institute of Space Power Sources, Shanghai 200245, China
Nannan Chen: Shanghai Key Lab of Materials Laser Processing and Modification, School of Materials Science and Engineering, Shanghai Jiao Tong University, Shanghai 200240, China
Min Wang: Shanghai Key Lab of Materials Laser Processing and Modification, School of Materials Science and Engineering, Shanghai Jiao Tong University, Shanghai 200240, China
Lin Wang: Shanghai Key Lab of Materials Laser Processing and Modification, School of Materials Science and Engineering, Shanghai Jiao Tong University, Shanghai 200240, China
Xunchun Wang: Shanghai Key Lab of Materials Laser Processing and Modification, School of Materials Science and Engineering, Shanghai Jiao Tong University, Shanghai 200240, China
Yan Cai: Shanghai Key Lab of Materials Laser Processing and Modification, School of Materials Science and Engineering, Shanghai Jiao Tong University, Shanghai 200240, China
Bin Qian: Shanghai Institute of Space Power Sources, Shanghai 200245, China
Xueming Hua: Shanghai Key Lab of Materials Laser Processing and Modification, School of Materials Science and Engineering, Shanghai Jiao Tong University, Shanghai 200240, China; Corresponding author.

Journal volume & issue: Vol. 26
pp. 3272 – 3284

Abstract

Read online

Reliability of joints in solar arrays significantly influences the service life of satellites. Interface between solar cell and interconnector experiences serious temperature cycling during space service which would further lead to failure. To further improve the interface joining thermal reliability, elucidation of the interface formation and corresponding microstructure evolution during thermal fatigue is necessary. In this study, parallel gap resistance welded (PGRW) multi-layered joint between GaAs solar cell and Ag foil are subjected to different temperature cycling tests (−160–120 °C, −165–160 °C) with various cycles. Obtained results confirm the joining mechanism of the joint as solid-solution interdiffusion between Ag foil and Au surface of solar cell electrode. Also, conducted temperature cycling essentially lead to thermal fatigue process at Ag/Au interface, therefore more serious interface strength degradation is generated by larger temperature cycling range. Joint failure is initiated by thermal fatigue induced dislocation and residual strain concentrations around dissimilar interface. And the large mismatch in coefficients of thermal expansion (CTE) of the multilayer structure amplifies the thermal fatigue effect.

Published in Journal of Materials Research and Technology

ISSN: 2238-7854 (Print); 2214-0697 (Online)
Publisher: Elsevier
Country of publisher: Netherlands
LCC subjects: Technology: Mining engineering. Metallurgy
Website: https://www.journals.elsevier.com/journal-of-materials-research-and-technology/

About the journal

Abstract

Keywords