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Life time analysis & accelerated aging tests

Florian Sutter, Johannes Wette, Arantxa Fernandez (Ciemat)

SFERA Summer School 16.5.2013

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Contents

Principles of degradation
Outdoor exposure testing
Accelerated aging testing
Service life time modeling
Conclusions and Outlook

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Motivation
The cost of corrosion
100MW power plant, 40% annual capacity factor
Annual electricity production: 100 MW 8760 h 0.4 = 350,400 MWh
1% mirror reflectance loss 3,504 MWh per year
490,560 US$ / year loss due to degradation (estimated feed-in tariff 0.14 US$/kWh)

Goals for improved optical materials

- >30 years lifetime
- >95% specular reflectance ( = 7.5 mrad)
- specular reflectance loss <1% over life time
- low manufacturing cost < 27 US$/m
[C. Kennedy NREL]

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Environmental material stresses during service life

Radiation

Mechanicalstresses
wind loads
stresses due to mounting

total solar radiation

especially UV-A, UV-B

Environmentalpollutants

chemical reactions with dust or sand

pollutants from surrounding industry
(e.g. coal plants)
proximity to sea

Temperature
cyclic day/night
temperature changes
frost

Humidity
ambient relative humidity
dew
rain

Abrasion
airborne dust or sand
cleaning mechanism

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Photodegradation of paint films

Initiation:
Photolisis
Propagation:
Autooxidation

UV radiation

RH

R + H

Bond cleavage to
form free radicals

R + O2

R O O

Peroxy radical
formation

R O O H + R

Peroxy radical attack

of polymer chain to
form hydroperoxide
and free radical

R O + O H

Fragmentation of
hydroperoxide

R O O + R H
UV radiation

R O O H
Termination:
Embrittlement

R + R

[Zeus; C.Hare, Journal of Protective Coatings and Linings]

R R

Interchain cross
linking
Yellowing
Reduced mechanical strength
Reduced impact resistance
Small surface cracks

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Thermal induced cracking and delamination

T > 0
2 < S < 1
2
1
Substrate s

coating

T Ecoating Substrate coating

1 coating

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Cracking and delamination

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Corrosion of metals
Differential aeration

0.3V

Corrosion pit

[U.R. Evans]
O2 + 2 H2O + 4e- 4 OH-

M M2+ + 2 e-

[L.Shreir]

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Corrosion of metals
Galvanic corrosion
Practical galvanic series 2)

Standard electrode potential 1)

Metal
Au
Ag
Cu
Sn
Pb
Fe
Cd
Zn
Cr
Ti
Al (99.5)
Mg
1)

V
+1.5
+0.8
+0.52
+0.15
-0.13
-0.36
-0.40
-0.76
-0.91
-1.21
-1.66
-2.36

25 C; 101,3 kPa; pH=0; effective ion activity= 1

based to the standard hydrogen electrode

Metal
Au
Ag
Cu
X5CrNi18.8
Ti
Sn
Cr
Pb
Steel 8.8
Cd
Al (99.5)
Zn
Mg
2)

V
+0.24
+0.15
+0.01
-0.05
-0.11
-0.19
-0.29
-0.30
-0.35
-0.52
-0.67
-0.80
-1.40

Potential in artificial sea water with pH 7,5

based to the standard hydrogen electrode

Galvanic corrosion appears at potential differences of 0.05 0.1 V

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Galvanic Corrosion

Galvanic corrosion
of aluminum layer

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Possible degradation silvered glass mirrors

UV-light

Glass 4mm

Silver
Copper
Low Pb protective lacquer
Pb free top coat

Galvanic dissolution of Cu
Embrittlement of lacquer
Delamination of paints
Corrosion of
unprotected silver

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Examples glass mirror corrosion in the field

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Examples glass mirror corrosion in the field

[NREL]

Corrosion can appear

<2 years in field

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Corrosion of aluminum reflectors

SiO2 sol-gel

TiO2
SiO2
Al

Corroded
Al-layer

Al2O3

NanoComposite

SiO2 - sol-gel protective coating

3m

PVDlayersystem

TiO2
SiO2
Al (99.99% purity)

60nm
95nm
65nm

Anodizinglayer

Al2O3

3m

0.5mm
Al-Substrate

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Corrosion of aluminum reflectors

O2

O2
Defect

Differential areation cell

O2 + 2H2O + 4 e- 4OH-

Crack due to H2-pressure

SiO2
SiO2

H2

TiO2
SiO2
Al
Al2O3

Al-Substrate
Cathodic reaction
O2 + 2H2O + 4 e- 4OHe
Hydrolysis
Al3+ + 3 H2O Al(OH)3+3H+

H2-formation
2H+ + 2 e- H2

Anodic reaction
Al Al3+ + 3 e-

Al

eAl2O3
Al Al3+ + 3 e-

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Examples aluminum corrosion

PVD reflector in contact with NaCl-solution

(50g/l), artificial defect

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Chemical reactions dust polymer coating

Transparent polymer coating

Lime rich dust Abu Dhabi

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Contents

Principles of degradation
Outdoor Exposure Tests
Accelerated aging testing
Service life time modeling
Conclusions and Outlook

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Outdoor Exposure Testing

Galvanic separation sample-rack

+ Covers all environmental stresses

Facing towards equator

+ Simple

45 tilt angle

- No acceleration
- Various exposure sites needed
- Requires partners
- Sample degradation during handling / shipping

[Q-lab]

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Outdoor exposure testing of aluminum prototype materials

Exposure program without cleaning of samples

Canary Islands

Abu Dhabi

Almera

Tabernas PSA

Exposure program to test influence of cleaning on sample degradation

Cleaning with pressurized

demineralized water

Cleaning with soft tissue

and demineralized water

No cleaning

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Specular reflectance losses (660nm,15,12.5mrad)

Exposure time: 4.6 - 6 months

6,0
5,0
4,0
3,0
2,0

Total loss per site

1,0

Abu Dhabi 16.6%

Almeria
12.7%
Tabernas 11.6%
Canarias 6.4 %

0,0

S0990C

S0992

S0990A

-1,0

Specular reflectance loss [%]

7,0

9 differently coated aluminum prototype materials

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Reflectance time dependence

Annual degradation rate ~ 0.2%/yr

Solar weighted hemispherical reflectance of Flabeg mirrors after outdoor exposure at NREL (Colorado), Arizona (APS),
Florida (FLA) and accelerated exposure in Ci65 (1 sun / 60C / 60%RH).
[C. Kennedy NREL]

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Contents

Principles of degradation
Outdoor Exposure Tests
Accelerated aging testing
Service life time modeling
Conclusions and Outlook

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Accelerated aging testing

Methods to accelerate degradation:

- Increase temperature to accelerate water diffusion
- Lower wavelengths to accelerate photodegradation (>280nm)
- Extreme temperature cycling to induce cracking, delamination
- Increase humidity / condensation cycles / exposure to pollutants (Cl-, S2-, OH-, H+)
- Increase mechanical abrasion of coatings

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Accelerated aging tests

IEC 62108 10.7a: Damp heat test 85/85
Chamber temperature:
Humidity:
Testing time:

85 2C
85 5 % relative humidity
1000 hours

IEC 62108 10.7b: Damp heat test 65/85

Chamber temperature:
Humidity:
Testing time:

65 2C
85 5 % relative humidity
2000 hours

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Accelerated aging tests

ISO 11507: UV+Water Test
Chamber temperature:
Humidity:
Radiation:
Cycle time:
Testing time:

50 to 60C
ambient to 100% relative humidity
lamp type II, UVA-340; 290-400 nm; peak emission at 340nm;
lamp power matches 1 sun
8 hours
>1000 hours

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Accelerated aging tests

ISO 9227: Neutral salt spray test (NSS)
Chamber temperature:
Humidity:
Sprayed solution:
Condensation rate:
Sample position:
Testing time:

35 2 C
constant 100% relative humidity
demineralized water + 50 g/l NaCl
(pH 6.5 7.2)
1.5 0.5 ml/h on a surface of 80 cm
20 5 respect to vertical
480 3500 hours

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Accelerated aging tests

ISO 9227: Copper accelerated salt spray test (CASS)
Chamber temperature:
Humidity:
Sprayed solution:
Condensation rate:
Sample position:
Testing time:

50 2 C
constant 100% relative humidity
demineralized water + 50 g/l NaCl + 0.26 g/l CuCl2
(pH 3.1 3.3)
1.5 0.5 ml/h on a surface of 80 cm
20 5 respect to vertical
120 480 hours

CuCl2

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Accelerated aging tests

DIN 50018 / ISO 6988: Kesternich Test
Chamber temperature:
Humidity:
Initial SO2 concentration:
Cycle time:
Testing time:

ambient / 40 3C
ambient / 100% relative humidity
0.33 or 0.67% of volume of testing chamber
24 hours
>20 cycles

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Accelerated aging tests

ISO 61215: Thermal Cycling
Chamber temperature:
Humidity:
Cycle duration:
Recommended cycle number:

-40C to +85C
dry
min. 2h 50min, max. 6h
>100

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Accelerated aging tests

Thermal Cycling with humidity based on ISO 6270-2CH
Chamber temperature:
Humidity:
Cycle duration:
Recommended cycle number:

-40C to +85C
ambient to 100% relative humidity
24 h
>20

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Accelerated aging tests

Humidity Freeze Test IEC 62108
Chamber temperature:
Humidity:
Precycling:
Cycle duration:
Freeze cycle number:
Total testing time:

-40C to +65C
ambient to 85% relative humidity
400 cycles
24 h
40
~2000h

400 precycles -40 to 65C, dry

40 humidity-freeze cycles

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Accelerated aging tests

Abrasion testing
Available standards:

Simulation of windblown
dust and sand particles

MIL-STD 810G, ISO 11998, DIN ISO 9211-4

Simulation of cleaning cycles

Scratching of coatings with

controlled normal force

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Accelerated aging of aluminum - Test comparison

Outdoors (5 months)

Salt spray (NSS)

>600h

Damp heat 85/85

1000h

UV+humidity

1000h

Corrosion at coating defects

Corrosion due to diffusion

+ Realistic defect corrosion

- Unrealistic side effects
- Long exposure time >2000 h

- Unrealistic degradation due

to high acceleration

+ Realistic corrosion due to diffusion

- Unrealistic cracking for some coatings
- Long exposure time

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Accelerated aging of aluminum Test comparison

86,0

NSS
UV+humidity

specular reflectance [%]

84,0

Damp Heat
Outdoor 6 months

82,0
80,0
78,0
76,0
74,0
72,0
70,0

500

1000

1500
Hours

2000

2500

3000

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Typical testing program for reflectors

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Contents

Principles of degradation
Outdoor Exposure Tests
Accelerated aging testing
Service life time modeling
Conclusions and Outlook

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Photodegradation of polymeric glazing materials

UV- light concentrator

385 nm

E t
t K UV e
E0
0
t

k BT ( t )

dt

EUV (t )

E , t d

290 nm

E0 = 44.5 W/m
K (s-1)
3.6
9.6e-5
[NREL, Khl et al. / Solar Energy 79 (2005) 618-623]

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Life time prediction model for a PVD aluminum reflector

k = 5.3 10-2 months-0.5

f c 1 exp k t
k = 6.4 10-3 months-0.5
k = 2.9 10-3 months-0.5
k = 1.1 10-3 months-0.5

0.25

0.49

0.94

2.02

3.12

months

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Life time prediction model for a PVD aluminum reflector

average reflectance of corroded area

t 0 1 exp k t 0 44.1% 0.04

Initial specular reflectance

%
%

t exp k t 0.057
t
months
months

Losses due to corrosion

Losses due to abrasion

0 = 86.5 for reflectors without sol gel

0 = 83.5 for reflectors with sol gel

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Correlation of Neutral Salt Spray test to outdoors

Exposure time in NSS-test tNSS [h]

Only valid for sol-gel coated

PVD aluminum reflectors!
10 years Florida 2200 h
10 years Golden 461 h
10 years Tabernas 67 h

Exposure time outdoors t [months]

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Conclusions and Outlook

- Accelerated aging tests are a useful tool to compare materials under defined
laboratory stresses
- At too high stresses unrealistic chemical processes may take place
- Comparison to Outdoor Exposure Tests recommended
- Service life time prediction models are semi-empirical. Mechanistic models are
aimed at but they are complex.
Further research required to
- Understand the degradation mechanisms of the several reflector types
- Improve existing accelerated aging tests (e.g. include reaction with dust)
- Define suited accelerated aging standard for CSP reflectors
- Correlate accelerated aging tests to reference outdoor sites for several materials