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157793 https://hdl.handle.net/2286/R.I.55495 http://rightsstatements.org/vocab/InC/1.0/ 2019 2021-12-16T11:56:02 ix, 58 pages : illustrations (some color) Masters Thesis Academic theses Text eng Sukumar Mony, Sujyot Holman, Zachary Alford, Terry Yu, Zhengshan Arizona State University Partial requirement for: M.S., Arizona State University, 2019 Includes bibliographical references (pages 49-52) Field of study: Materials science and engineering Interconnection methods for IBC photovoltaic (PV) module integration have widely been explored yet a concrete and cost-effective solution has yet to be found. Traditional methods of tabbing and stringing which are still being used today impart increased stress on the cells, not to mention the high temperatures induced during the soldering process as well. In this work and effective and economical interconnection method is demonstrated, by laser welding an embossed aluminum (Al) electrode layer to screen-printed silver (Ag) on the solar cell. Contact resistivity below 1mΩ.cm2 is measured with the proposed design. Cross-sectional analysis of interfaces is conducted via Scanning Electron Microscopy (SEM) and Energy Dispersive X-ray Spectroscopy (EDXS) methods. Typical laser weld phenomenon observed involves Al ejection at the entrance of the weld, followed by Al and Ag fusing together mid-way through the weld spot, as revealed by cross-sectional depth analysis. The effects of voltage and lamp intensity are also tested on the welding process. With the range of voltages tested, 240V seems to show the least process variability and the most uniform contact between Al and Ag layers, upon using an Ethylene-Vinyl Acetate (EVA) encapsulant. Two lamp intensities were also explored with a Polyolefin (POE) encapsulant with Al and Ag layers seen welded together as well. Smaller effect sizes at lamp 2 intensity showed better contact. A process variability analysis was conducted to understand the effects of the two different lamps on welds being formed. Lamp 2 showed a bi-modal size distribution with a higher peak intensity, with more pulses coupling into the sample, as compared to lamp 1. Materials Science Applied physics Energy Electron Microscopy IBC Laser welding Solar Cells Solar Cells Interconnects (Integrated circuit technology) Transducers, Interdigital Laser welding Scanning electron microscopy X-ray spectroscopy Investigation into a laser welded interconnection method for Interdigitated Back Contact (IBC) solar cell modules