For many decades, nuclear fusion power has been viewed as the ultimate energy source. A fusion power plant could generate carbon-free energy at a scale needed to address climate change. And it could be fueled by deuterium recovered from an essentially endless source — seawater.

Decades of work and billions of dollars in research funding have yielded many advances, but challenges remain. To Ju Li, the TEPCO Professor in Nuclear Science and Engineering and a professor of materials science and engineering at MIT, there are still two big challenges. The first is to build a fusion power plant that generates more energy than is put into it; in other words, it produces a net output of power. Researchers worldwide are making progress toward meeting that goal.

The second challenge that Li cites sounds straightforward: “How do we get the heat out?” But understanding the problem and finding a solution are both far from obvious.

Research in the MIT Energy Initiative (MITEI) includes development and testing of advanced materials that may help address those challenges, as well as many other challenges of the energy transition. MITEI has multiple corporate members that have been supporting MIT’s efforts to advance technologies required to harness fusion energy.

The problem: An abundance of helium, a destructive force

Key to a fusion reactor is a superheated plasma — an ionized gas — that’s reacting inside a vacuum vessel. As light atoms in the plasma combine to form heavier ones, they release fast neutrons with high kinetic energy that shoot through the surrounding vacuum vessel into a coolant. During this process, those fast neutrons gradually lose their energy by causing radiation damage and generating heat. The heat that’s transferred to the coolant is eventually used to raise steam that drives an electricity-generating turbine.

The problem is finding a material for the vacuum vessel that remains strong enough to keep the reacting plasma and the coolant apart, while allowing the fast neutrons to pass through to the coolant. If one considers only the damage due to neutrons knocking atoms out of position in the metal structure, the vacuum vessel should last a full decade. However, depending on what materials are used in the fabrication of the vacuum vessel, some projections indicate that the vacuum vessel will last only six to 12 months. Why is that? Today’s nuclear fission reactors also generate neutrons, and those reactors last far longer than a year.

The difference is that fusion neutrons possess much higher kinetic energy than fission neutrons do, and as they penetrate the vacuum vessel walls, some of them interact with the nuclei of atoms in the structural material, giving off particles that rapidly turn into helium atoms. The result is hundreds of times more helium atoms than are present in a fission reactor. Those helium atoms look for somewhere to land — a place with low “embedding energy,” a measure that indicates how much energy it takes for a helium atom to be absorbed. As Li explains, “The helium atoms like to go to places with low helium embedding energy.” And in the metals used in fusion vacuum vessels, there are places with relatively low helium embedding energy — namely, naturally occurring openings called grain boundaries.

Metals are made up of individual grains inside which atoms are lined up in an orderly fashion. Where the grains come together there are gaps where the atoms don’t line up as well. That open space has relatively low helium embedding energy, so the helium atoms congregate there. Worse still, helium atoms have a repellent interaction with other atoms, so the helium atoms basically push open the grain boundary. Over time, the opening grows into a continuous crack, and the vacuum vessel breaks.

That congregation of helium atoms explains why the structure fails much sooner than expected based just on the number of helium atoms that are present. Li offers an analogy to illustrate. “Babylon is a city of a million people. But the claim is that 100 bad persons can destroy the whole city — if all those bad persons work at the city hall.” The solution? Give those bad persons other, more attractive places to go, ideally in their own villages.

To Li, the problem and possible solution are the same in a fusion reactor. If many helium atoms go to the grain boundary at once, they can destroy the metal wall. The solution? Add a small amount of a material that has a helium embedding energy even lower than that of the grain boundary. And over the past two years, Li and his team have demonstrated — both theoretically and experimentally — that their diversionary tactic works. By adding nanoscale particles of a carefully selected second material to the metal wall, they’ve found they can keep the helium atoms that form from congregating in the structurally vulnerable grain boundaries in the metal.

Looking for helium-absorbing compounds

To test their idea, So Yeon Kim ScD ’23 of the Department of Materials Science and Engineering and Haowei Xu PhD ’23 of the Department of Nuclear Science and Engineering acquired a sample composed of two materials, or “phases,” one with a lower helium embedding energy than the other. They and their collaborators then implanted helium ions into the sample at a temperature similar to that in a fusion reactor and watched as bubbles of helium formed. Transmission electron microscope images confirmed that the helium bubbles occurred predominantly in the phase with the lower helium embedding energy. As Li notes, “All the damage is in that phase — evidence that it protected the phase with the higher embedding energy.”

Having confirmed their approach, the researchers were ready to search for helium-absorbing compounds that would work well with iron, which is often the principal metal in vacuum vessel walls. “But calculating helium embedding energy for all sorts of different materials would be computationally demanding and expensive,” says Kim. “We wanted to find a metric that is easy to compute and a reliable indicator of helium embedding energy.”

They found such a metric: the “atomic-scale free volume,” which is basically the maximum size of the internal vacant space available for helium atoms to potentially settle. “This is just the radius of the largest sphere that can fit into a given crystal structure,” explains Kim. “It is a simple calculation.” Examination of a series of possible helium-absorbing ceramic materials confirmed that atomic free volume correlates well with helium embedding energy. Moreover, many of the ceramics they investigated have higher free volume, thus lower embedding energy, than the grain boundaries do.

However, in order to identify options for the nuclear fusion application, the screening needed to include some other factors. For example, in addition to the atomic free volume, a good second phase must be mechanically robust (able to sustain a load); it must not get very radioactive with neutron exposure; and it must be compatible — but not too cozy — with the surrounding metal, so it disperses well but does not dissolve into the metal. “We want to disperse the ceramic phase uniformly in the bulk metal to ensure that all grain boundary regions are close to the dispersed ceramic phase so it can provide protection to those regions,” says Li. “The two phases need to coexist, so the ceramic won’t either clump together or totally dissolve in the iron.”

Using their analytical tools, Kim and Xu examined about 50,000 compounds and identified 750 potential candidates. Of those, a good option for inclusion in a vacuum vessel wall made mainly of iron was iron silicate.

Experimental testing

The researchers were ready to examine samples in the lab. To make the composite material for proof-of-concept demonstrations, Kim and collaborators dispersed nanoscale particles of iron silicate into iron and implanted helium into that composite material. She took X-ray diffraction (XRD) images before and after implanting the helium and also computed the XRD patterns. The ratio between the implanted helium and the dispersed iron silicate was carefully controlled to allow a direct comparison between the experimental and computed XRD patterns. The measured XRD intensity changed with the helium implantation exactly as the calculations had predicted. “That agreement confirms that atomic helium is being stored within the bulk lattice of the iron silicate,” says Kim.

To follow up, Kim directly counted the number of helium bubbles in the composite. In iron samples without the iron silicate added, grain boundaries were flanked by many helium bubbles. In contrast, in the iron samples with the iron silicate ceramic phase added, helium bubbles were spread throughout the material, with many fewer occurring along the grain boundaries. Thus, the iron silicate had provided sites with low helium-embedding energy that lured the helium atoms away from the grain boundaries, protecting those vulnerable openings and preventing cracks from opening up and causing the vacuum vessel to fail catastrophically.

The researchers conclude that adding just 1 percent (by volume) of iron silicate to the iron walls of the vacuum vessel will cut the number of helium bubbles in half and also reduce their diameter by 20 percent — “and having a lot of small bubbles is OK if they’re not in the grain boundaries,” explains Li.

Next steps

Thus far, Li and his team have gone from computational studies of the problem and a possible solution to experimental demonstrations that confirm their approach. And they’re well on their way to commercial fabrication of components. “We’ve made powders that are compatible with existing commercial 3D printers and are preloaded with helium-absorbing ceramics,” says Li. The helium-absorbing nanoparticles are well dispersed and should provide sufficient helium uptake to protect the vulnerable grain boundaries in the structural metals of the vessel walls. While Li confirms that there’s more scientific and engineering work to be done, he, along with Alexander O'Brien PhD ’23 of the Department of Nuclear Science and Engineering and Kang Pyo So, a former postdoc in the same department, have already developed a startup company that’s ready to 3D print structural materials that can meet all the challenges faced by the vacuum vessel inside a fusion reactor.

This research was supported by Eni S.p.A. through the MIT Energy Initiative. Additional support was provided by a Kwajeong Scholarship; the U.S. Department of Energy (DOE) Laboratory Directed Research and Development program at Idaho National Laboratory; U.S. DOE Lawrence Livermore National Laboratory; and Creative Materials Discovery Program through the National Research Foundation of Korea.

The scorching surface of Venus, where temperatures can climb to 480 degrees Celsius (hot enough to melt lead), is an inhospitable place for humans and machines alike. One reason scientists have not yet been able to send a rover to the planet’s surface is because silicon-based electronics can’t operate in such extreme temperatures for an extended period of time.

For high-temperature applications like Venus exploration, researchers have recently turned to gallium nitride, a unique material that can withstand temperatures of 500 degrees or more.

The material is already used in some terrestrial electronics, like phone chargers and cell phone towers, but scientists don’t have a good grasp of how gallium nitride devices would behave at temperatures beyond 300 degrees, which is the operational limit of conventional silicon electronics.

In a new paper published in Applied Physics Letters, which is part of a multiyear research effort, a team of scientists from MIT and elsewhere sought to answer key questions about the material’s properties and performance at extremely high temperatures.  

They studied the impact of temperature on the ohmic contacts in a gallium nitride device. Ohmic contacts are key components that connect a semiconductor device with the outside world.

The researchers found that extreme temperatures didn’t cause significant degradation to the gallium nitride material or contacts. They were surprised to see that the contacts remained structurally intact even when held at 500 degrees Celsius for 48 hours.

Understanding how contacts perform at extreme temperatures is an important step toward the group’s next goal of developing high-performance transistors that could operate on the surface of Venus. Such transistors could also be used on Earth in electronics for applications like extracting geothermal energy or monitoring the inside of jet engines.

“Transistors are the heart of most modern electronics, but we didn’t want to jump straight to making a gallium nitride transistor because so much could go wrong. We first wanted to make sure the material and contacts could survive, and figure out how much they change as you increase the temperature. We’ll design our transistor from these basic material building blocks,” says John Niroula, an electrical engineering and computer science (EECS) graduate student and lead author of the paper.

His co-authors include Qingyun Xie PhD ’24; Mengyang Yuan PhD ’22; EECS graduate students Patrick K. Darmawi-Iskandar and Pradyot Yadav; Gillian K. Micale, a graduate student in the Department of Materials Science and Engineering; senior author Tomás Palacios, the Clarence J. LeBel Professor of EECS, director of the Microsystems Technology Laboratories, and a member of the Research Laboratory of Electronics; as well as collaborators Nitul S. Rajput of the Technology Innovation Institute of the United Arab Emirates; Siddharth Rajan of Ohio State University; Yuji Zhao of Rice University; and Nadim Chowdhury of Bangladesh University of Engineering and Technology.

Turning up the heat

While gallium nitride has recently attracted much attention, the material is still decades behind silicon when it comes to scientists’ understanding of how its properties change under different conditions. One such property is resistance, the flow of electrical current through a material.

A device’s overall resistance is inversely proportional to its size. But devices like semiconductors have contacts that connect them to other electronics. Contact resistance, which is caused by these electrical connections, remains fixed no matter the size of the device. Too much contact resistance can lead to higher power dissipation and slower operating frequencies for electronic circuits.

“Especially when you go to smaller dimensions, a device’s performance often ends up being limited by contact resistance. People have a relatively good understanding of contact resistance at room temperature, but no one has really studied what happens when you go all the way up to 500 degrees,” Niroula says.

For their study, the researchers used facilities at MIT.nano to build gallium nitride devices known as transfer length method structures, which are composed of a series of resistors. These devices enable them to measure the resistance of both the material and the contacts.

They added ohmic contacts to these devices using the two most common methods. The first involves depositing metal onto gallium nitride and heating it to 825 degrees Celsius for about 30 seconds, a process called annealing.

The second method involves removing chunks of gallium nitride and using a high-temperature technology to regrow highly doped gallium nitride in its place, a process led by Rajan and his team at Ohio State. The highly doped material contains extra electrons that can contribute to current conduction.

“The regrowth method typically leads to lower contact resistance at room temperature, but we wanted to see if these methods still work well at high temperatures,” Niroula says.

A comprehensive approach

They tested devices in two ways. Their collaborators at Rice University, led by Zhao, conducted short-term tests by placing devices on a hot chuck that reached 500 degrees Celsius and taking immediate resistance measurements.

At MIT, they conducted longer-term experiments by placing devices into a specialized furnace the group previously developed. They left devices inside for up to 72 hours to measure how resistance changes as a function of temperature and time.

Microscopy experts at MIT.nano (Aubrey N. Penn) and the Technology Innovation Institute (Nitul S. Rajput) used state-of-the-art transmission electron microscopes to see how such high temperatures affect gallium nitride and the ohmic contacts at the atomic level.

“We went in thinking the contacts or the gallium nitride material itself would degrade significantly, but we found the opposite. Contacts made with both methods seemed to be remarkably stable,” says Niroula.

While it is difficult to measure resistance at such high temperatures, their results indicate that contact resistance seems to remain constant even at temperatures of 500 degrees, for around 48 hours. And just like at room temperature, the regrowth process led to better performance.

The material did start to degrade after being in the furnace for 48 hours, but the researchers are already working to boost long-term performance. One strategy involves adding protective insulators to keep the material from being directly exposed to the high-temperature environment.

Moving forward, the researchers plan to use what they learned in these experiments to develop high-temperature gallium nitride transistors.

“In our group, we focus on innovative, device-level research to advance the frontiers of microelectronics, while adopting a systematic approach across the hierarchy, from the material level to the circuit level. Here, we have gone all the way down to the material level to understand things in depth. In other words, we have translated device-level advancements to circuit-level impact for high-temperature electronics, through design, modeling and complex fabrication. We are also immensely fortunate to have forged close partnerships with our longtime collaborators in this journey,” Xie says.

This work was funded, in part, by the U.S. Air Force Office of Scientific Research, Lockheed Martin Corporation, the Semiconductor Research Corporation through the U.S. Defense Advanced Research Projects Agency, the U.S. Department of Energy, Intel Corporation, and the Bangladesh University of Engineering and Technology.

Fabrication and microscopy were conducted at MIT.nano, the Semiconductor Epitaxy and Analysis Laboratory at Ohio State University, the Center for Advanced Materials Characterization at the University of Oregon, and the Technology Innovation Institute of the United Arab Emirates.

Consider the dizzying ascent of solar energy in the United States: In the past decade, solar capacity increased nearly 900 percent, with electricity production eight times greater in 2023 than in 2014. The jump from 2022 to 2023 alone was 51 percent, with a record 32 gigawatts (GW) of solar installations coming online. In the past four years, more solar has been added to the grid than any other form of generation. Installed solar now tops 179 GW, enough to power nearly 33 million homes. The U.S. Department of Energy (DOE) is so bullish on the sun that its decarbonization plans envision solar satisfying 45 percent of the nation’s electricity demands by 2050.

But the continued rapid expansion of solar requires advances in technology, notably to improve the efficiency and durability of solar photovoltaic (PV) materials and manufacturing. That’s where Optigon, a three-year-old MIT spinout company, comes in.

“Our goal is to build tools for research and industry that can accelerate the energy transition,” says Dane deQuilettes, the company’s co-founder and chief science officer. “The technology we have developed for solar will enable measurements and analysis of materials as they are being made both in lab and on the manufacturing line, dramatically speeding up the optimization of PV.”

With roots in MIT’s vibrant solar research community, Optigon is poised for a 2024 rollout of technology it believes will drastically pick up the pace of solar power and other clean energy projects.

Beyond silicon

Silicon, the material mainstay of most PV, is limited by the laws of physics in the efficiencies it can achieve converting photons from the sun into electrical energy. Silicon-based solar cells can theoretically reach power conversion levels of just 30 percent, and real-world efficiency levels hover in the low 20s. But beyond the physical limitations of silicon, there is another issue at play for many researchers and the solar industry in the United States and elsewhere: China dominates the silicon PV market, from supply chains to manufacturing.

Scientists are eagerly pursuing alternative materials, either for enhancing silicon’s solar conversion capacity or for replacing silicon altogether.

In the past decade, a family of crystal-structured semiconductors known as perovskites has risen to the fore as a next-generation PV material candidate. Perovskite devices lend themselves to a novel manufacturing process using printing technology that could circumvent the supply chain juggernaut China has built for silicon. Perovskite solar cells can be stacked on each other or layered atop silicon PV, to achieve higher conversion efficiencies. Because perovskite technology is flexible and lightweight, modules can be used on roofs and other structures that cannot support heavier silicon PV, lowering costs and enabling a wider range of building-integrated solar devices.

But these new materials require testing, both during R&D and then on assembly lines, where missing or defective optical, electrical, or dimensional properties in the nano-sized crystal structures can negatively impact the end product.

“The actual measurement and data analysis processes have been really, really slow, because you have to use a bunch of separate tools that are all very manual,” says Optigon co-founder and chief executive officer Anthony Troupe ’21. “We wanted to come up with tools for automating detection of a material’s properties, for determining whether it could make a good or bad solar cell, and then for optimizing it.”

“Our approach packed several non-contact, optical measurements using different types of light sources and detectors into a single system, which together provide a holistic, cross-sectional view of the material,” says Brandon Motes ’21, ME ’22, co-founder and chief technical officer.

“This breakthrough in achieving millisecond timescales for data collection and analysis means we can take research-quality tools and actually put them on a full production system, getting extremely detailed information about products being built at massive, gigawatt scale in real-time,” says Troupe.

This streamlined system takes measurements “in the snap of the fingers, unlike the traditional tools,” says Joseph Berry, director of the US Manufacturing of Advanced Perovskites Consortium and a senior research scientist at the National Renewable Energy Laboratory. “Optigon’s techniques are high precision and allow high throughput, which means they can be used in a lot of contexts where you want rapid feedback and the ability to develop materials very, very quickly.”

According to Berry, Optigon’s technology may give the solar industry not just better materials, but the ability to pump out high-quality PV products at a brisker clip than is currently possible. “If Optigon is successful in deploying their technology, then we can more rapidly develop the materials that we need, manufacturing with the requisite precision again and again,” he says. “This could lead to the next generation of PV modules at a much, much lower cost.”

Measuring makes the difference

With Small Business Innovation Research funding from DOE to commercialize its products and a grant from the Massachusetts Clean Energy Center, Optigon has settled into a space at the climate technology incubator Greentown Labs in Somerville, Massachusetts. Here, the team is preparing for this spring’s launch of its first commercial product, whose genesis lies in MIT’s GridEdge Solar Research Program.

Led by Vladimir Bulović, a professor of electrical engineering and the director of MIT.nano, the GridEdge program was established with funding from the Tata Trusts to develop lightweight, flexible, and inexpensive solar cells for distribution to rural communities around the globe. When deQuilettes joined the group in 2017 as a postdoc, he was tasked with directing the program and building the infrastructure to study and make perovskite solar modules.

“We were trying to understand once we made the material whether or not it was good,” he recalls. “There were no good commercial metrology [the science of measurements] tools for materials beyond silicon, so we started to build our own.” Recognizing the group’s need for greater expertise on the problem, especially in the areas of electrical, software, and mechanical engineering, deQuilettes put a call out for undergraduate researchers to help build metrology tools for new solar materials.

“Forty people inquired, but when I met Brandon and Anthony, something clicked; it was clear we had a complementary skill set,” says deQuilettes. “We started working together, with Anthony coming up with beautiful designs to integrate multiple measurements, and Brandon creating boards to control all of the hardware, including different types of lasers. We started filing multiple patents and that was when we saw it all coming together.”

“We knew from the start that metrology could vastly improve not just materials, but production yields,” says Troupe. Adds deQuilettes, “Our goal was getting to the highest performance orders of magnitude faster than it would ordinarily take, so we developed tools that would not just be useful for research labs but for manufacturing lines to give live feedback on quality.”

The device Optigon designed for industry is the size of a football, “with sensor packages crammed into a tiny form factor, taking measurements as material flows directly underneath,” says Motes. “We have also thought carefully about ways to make interaction with this tool as seamless and, dare I say, as enjoyable as possible, streaming data to both a dashboard an operator can watch and to a custom database.”

Photovoltaics is just the start

The company may have already found its market niche. “A research group paid us to use our in-house prototype because they have such a burning need to get these sorts of measurements,” says Troupe, and according to Motes, “Potential customers ask us if they can buy the system now.” deQuilettes says, “Our hope is that we become the de facto company for doing any sort of characterization metrology in the United States and beyond.”

Challenges lie ahead for Optigon: product launches, full-scale manufacturing, technical assistance, and sales. Greentown Labs offers support, as does MIT’s own rich community of solar researchers and entrepreneurs. But the founders are already thinking about next phases.

“We are not limiting ourselves to the photovoltaics area,” says deQuilettes. “We’re planning on working in other clean energy materials such as batteries and fuel cells.”

That’s because the team wants to make the maximum impact on the climate challenge. “We’ve thought a lot about the potential our tools will have on reducing carbon emissions, and we’ve done a really in-depth analysis looking at how our system can increase production yields of solar panels and other energy technologies, reducing materials and energy wasted in conventional optimization,” deQuilettes says. “If we look across all these sectors, we can expect to offset about 1,000 million metric tons of CO₂ [carbon dioxide] per year in the not-too-distant future.”

The team has written scale into its business plan. “We want to be the key enabler for bringing these new energy technologies to market,” says Motes. “We envision being deployed on every manufacturing line making these types of materials. It’s our goal to walk around and know that if we see a solar panel deployed, there’s a pretty high likelihood that it will be one we measured at some point.”

Perovskites, a broad class of compounds with a particular kind of crystal structure, have long been seen as a promising alternative or supplement to today’s silicon or cadmium telluride solar panels. They could be far more lightweight and inexpensive, and could be coated onto virtually any substrate, including paper or flexible plastic that could be rolled up for easy transport.

In their efficiency at converting sunlight to electricity, perovskites are becoming comparable to silicon, whose manufacture still requires long, complex, and energy-intensive processes. One big remaining drawback is longevity: They tend to break down in a matter of months to years, while silicon solar panels can last more than two decades. And their efficiency over large module areas still lags behind silicon. Now, a team of researchers at MIT and several other institutions has revealed ways to optimize efficiency and better control degradation, by engineering the nanoscale structure of perovskite devices.

The study reveals new insights on how to make high-efficiency perovskite solar cells, and also provides new directions for engineers working to bring these solar cells to the commercial marketplace. The work is described today in the journal Nature Energy, in a paper by Dane deQuilettes, a recent MIT postdoc who is now co-founder and chief science officer of the MIT spinout Optigon, along with MIT professors Vladimir Bulovic and Moungi Bawendi, and 10 others at MIT and in Washington state, the U.K., and Korea.

“Ten years ago, if you had asked us what would be the ultimate solution to the rapid development of solar technologies, the answer would have been something that works as well as silicon but whose manufacturing is much simpler,” Bulovic says. “And before we knew it, the field of perovskite photovoltaics appeared. They were as efficient as silicon, and they were as easy to paint on as it is to paint on a piece of paper. The result was tremendous excitement in the field.”

Nonetheless, “there are some significant technical challenges of handling and managing this material in ways we’ve never done before,” he says. But the promise is so great that many hundreds of researchers around the world have been working on this technology. The new study looks at a very small but key detail: how to “passivate” the material’s surface, changing its properties in such a way that the perovskite no longer degrades so rapidly or loses efficiency.

“The key is identifying the chemistry of the interfaces, the place where the perovskite meets other materials,” Bulovic says, referring to the places where different materials are stacked next to perovskite in order to facilitate the flow of current through the device.

Engineers have developed methods for passivation, for example by using a solution that creates a thin passivating coating. But they’ve lacked a detailed understanding of how this process works — which is essential to make further progress in finding better coatings. The new study “addressed the ability to passivate those interfaces and elucidate the physics and science behind why this passivation works as well as it does,” Bulovic says.

The team used some of the most powerful instruments available at laboratories around the world to observe the interfaces between the perovskite layer and other materials, and how they develop, in unprecedented detail. This close examination of the passivation coating process and its effects resulted in “the clearest roadmap as of yet of what we can do to fine-tune the energy alignment at the interfaces of perovskites and neighboring materials,” and thus improve their overall performance, Bulovic says.

While the bulk of a perovskite material is in the form of a perfectly ordered crystalline lattice of atoms, this order breaks down at the surface. There may be extra atoms sticking out or vacancies where atoms are missing, and these defects cause losses in the material’s efficiency. That’s where the need for passivation comes in.

“This paper is essentially revealing a guidebook for how to tune surfaces, where a lot of these defects are, to make sure that energy is not lost at surfaces,” deQuilettes says. “It’s a really big discovery for the field,” he says. “This is the first paper that demonstrates how to systematically control and engineer surface fields in perovskites.”

The common passivation method is to bathe the surface in a solution of a salt called hexylammonium bromide, a technique developed at MIT several years ago by Jason Jungwan Yoo PhD ’20, who is a co-author of this paper, that led to multiple new world-record efficiencies. By doing that “you form a very thin layer on top of your defective surface, and that thin layer actually passivates a lot of the defects really well,” deQuilettes says. “And then the bromine, which is part of the salt, actually penetrates into the three-dimensional layer in a controllable way.” That penetration helps to prevent electrons from losing energy to defects at the surface.

These two effects, produced by a single processing step, produces the two beneficial changes simultaneously. “It’s really beautiful because usually you need to do that in two steps,” deQuilettes says.

The passivation reduces the energy loss of electrons at the surface after they have been knocked loose by sunlight. These losses reduce the overall efficiency of the conversion of sunlight to electricity, so reducing the losses boosts the net efficiency of the cells.

That could rapidly lead to improvements in the materials’ efficiency in converting sunlight to electricity, he says. The recent efficiency records for a single perovskite layer, several of them set at MIT, have ranged from about 24 to 26 percent, while the maximum theoretical efficiency that could be reached is about 30 percent, according to deQuilettes.

An increase of a few percent may not sound like much, but in the solar photovoltaic industry such improvements are highly sought after. “In the silicon photovoltaic industry, if you’re gaining half of a percent in efficiency, that’s worth hundreds of millions of dollars on the global market,” he says. A recent shift in silicon cell design, essentially adding a thin passivating layer and changing the doping profile, provides an efficiency gain of about half of a percent. As a result, “the whole industry is shifting and rapidly trying to push to get there.” The overall efficiency of silicon solar cells has only seen very small incremental improvements for the last 30 years, he says.

The record efficiencies for perovskites have mostly been set in controlled laboratory settings with small postage-stamp-size samples of the material. “Translating a record efficiency to commercial scale takes a long time,” deQuilettes says. “Another big hope is that with this understanding, people will be able to better engineer large areas to have these passivating effects.”

There are hundreds of different kinds of passivating salts and many different kinds of perovskites, so the basic understanding of the passivation process provided by this new work could help guide researchers to find even better combinations of materials, the researchers suggest. “There are so many different ways you could engineer the materials,” he says.

“I think we are on the doorstep of the first practical demonstrations of perovskites in the commercial applications,” Bulovic says. “And those first applications will be a far cry from what we’ll be able to do a few years from now.” He adds that perovskites “should not be seen as a displacement of silicon photovoltaics. It should be seen as an augmentation — yet another way to bring about more rapid deployment of solar electricity.”

“A lot of progress has been made in the last two years on finding surface treatments that improve perovskite solar cells,” says Michael McGehee, a professor of chemical engineering at the University of Colorado who was not associated with this research. “A lot of the research has been empirical with the mechanisms behind the improvements not being fully understood. This detailed study shows that treatments can not only passivate defects, but can also create a surface field that repels carriers that should be collected at the other side of the device. This understanding might help further improve the interfaces.”

The team included researchers at the Korea Research Institute of Chemical Technology, Cambridge University, the University of Washington in Seattle, and Sungkyunkwan University in Korea. The work was supported by the Tata Trust, the MIT Institute for Soldier Nanotechnologies, the U.S. Department of Energy, and the U.S. National Science Foundation.

A maze of brackish and freshwater ponds covers Taiwan’s coastal plain, supporting aquaculture operations that produce roughly NT $30 billion (US $920 million) worth of seafood every year. Taiwan’s government is hoping that the more than 400 square kilometers of fishponds can simultaneously produce a second harvest: solar power.

What is aquavoltaics?

That’s the impetus behind the new 42.9-megawatt aquavoltaics facility in the southern city of Tainan. To build it, Taipei-based Hongde Renewable Energy bought 57.6 hectares of abandoned land in Tainan’s fishpond-rich Qigu district, created earthen berms to delineate the two dozen ponds, and installed solar panels along the berms and over six reservoir ponds.

Tony Chang, general manager of the Hongde subsidiary Star Aquaculture, says 18 of the ponds are stocked with mullet (prized for their roe) and shrimp, while milkfish help clean the water in the reservoir ponds. In 2023, the first full year of operation, Chang says his team harvested over 100,000 kilograms of seafood. This August, they began stocking a cavernous indoor facility, also festooned with photovoltaics, to cultivate white-legged shrimp.

A number of other countries have been experimenting with aquavoltaics, including China, Chile, Bangladesh, and Norway, extending the concept to large solar arrays floating on rivers and bays. But nowhere else is the pairing of aquaculture and solar power seen as so crucial to the economy. Taiwan is striving to massively expand renewable generation to sustain its semiconductor fabs, and solar is expected to play a large role. But on this densely populated island—slightly larger than Maryland, smaller than the Netherlands—there’s not a lot of open space to install solar panels. The fishponds are hard to ignore. By the end of 2025, the government is looking to install 4.4 gigawatts of aquavoltaics to help meet its goal of 20 GW of solar generation.

Is Taiwan’s aquavoltaics plan unrealistic?

Meanwhile, though, solar developers are struggling to deliver on Taiwan’s ambitious goals, even as some projections suggest Taiwan will need over eight times more solar by 2050. And aquavoltaics in particular have come under scrutiny from environmental groups. In 2020, for example, reporter Cai Jiashan visited 100 solar plants built on agricultural land, including fishponds, and found dozens of cases where solar developers built more solar capacity than the law intended, or secured permits based on promises of continued farming that weren’t kept.

Star Aquaculture grows milkfish to help clean water for its breeding ponds.HDRenewables

On 7 July 2020, Taiwan’s Ministry of Agriculture responded by restricting solar development on farmland, in what the solar industry called the “Double-Seven Incident.” Many aquavoltaic projects were canceled while others were delayed. The latter included a 10-MW facility in Tainan that Google had announced to great fanfare in 2019 as its first renewable-energy investment in Asia, to supply power for the company’s Taiwan data centers. The array finally started up in 2023, three years behind schedule.

Critics of Taiwan’s renewed aquavoltaic plans thus see the government’s goal as unrealistic. Yuping Chen, executive director of the Taiwan Environment and Planning Association, a Taipei-based nonprofit dedicated to resolving conflicts between solar energy and agriculture, says of aquavoltaics, “It is claimed to be crucial by the government, but it’s impossible to realize.”

How aquavoltaics could revive fishing, boost revenue

Solar developers and government officials who endorse aquavoltaics argue that such projects could revive the island’s traditional fishing community. Taiwan’s fishing villages are aging and shrinking as younger people take city jobs. Climate change has also taken a toll. Severe storms damage fishpond embankments, while extreme heat and rainfall stress the fish.

4.4

Gigawatts of aquavoltaics that Taiwan wants to install by the end of 2025

Solar development could help reverse these trends. Several recent studies examining fishponds in Taiwan found that adding solar improves profitability, providing an opportunity to reinvigorate communities if agrivoltaic investors share their returns. Alan Wu, deputy director of the Green Energy Initiative at Taiwan’s Industrial Technology Research Institute, says the Hsinchu-based lab has opened a research station in Tainan to connect solar and aquaculture firms. ITRI is helping aquavoltaics facilities boost their revenues by figuring out how they can raise “species of high economic value that are normally more difficult to raise,” Wu says.

Such high-value products include the 27,000 pieces of sun-dried mullet roe that Hongde Renewable Energy’s Tainan site produced last year. The new indoor facility, meanwhile, should boost yields of the relatively pricey whiteleg shrimp. Chang expects the indoor harvests to fetch $500,000 to $600,000 annually, compared to $800,000 to $900,000 from the larger outdoor ponds.

The solar roof over the 100,000-liter indoor growth tanks protects the 2.7 million shrimp against weather and bird droppings. Chang says a patent-pending drain mechanically removes waste from each tank, and also sucks out the shrimp when they’re ready for harvest.

Land that Star Aquaculture set aside for wildlife now attracts endangered birds like the black-faced spoonbill [left] and the oriental stork [right].iStock (2)

The company has also set aside 9 percent of the site for wildlife, in response to concerns from conservationists. “Egrets, endangered oriental storks, and black-faced spoonbills continue to use the site,” Chang says. “If it was all covered with PV, it could impact their habitat.”

Such measures may not satisfy environmentalists, though. In a review published last month, researchers at Fudan University in Shanghai and two Chinese power firms concluded that China’s floating aquavoltaic installations—some of which already span 5 square kilometers—will “inevitably” alter the marine environment.

Aquavoltaic facilities that are entirely indoors may be an even harder sell as they scale up. Toshiba is backing such a plant in Tainan, to generate 120 MW for an unspecified “semiconductor manufacturer,” with plans for a 360-MW expansion. The resulting buildings could exclude wildlife from 5 square kilometers of habitat. Indoor projects could compensate by protecting land elsewhere. But, as Chen of the Taiwan Environment and Planning Association notes, developers of such sites may not take such measures unless they’re required by law to do so.

The scorching surface of Venus, where temperatures can climb to 480 degrees Celsius (hot enough to melt lead), is an inhospitable place for humans and machines alike. One reason scientists have not yet been able to send a rover to the planet’s surface is because silicon-based electronics can’t operate in such extreme temperatures for an extended period of time.

For high-temperature applications like Venus exploration, researchers have recently turned to gallium nitride, a unique material that can withstand temperatures of 500 degrees or more.

The material is already used in some terrestrial electronics, like phone chargers and cell phone towers, but scientists don’t have a good grasp of how gallium nitride devices would behave at temperatures beyond 300 degrees, which is the operational limit of conventional silicon electronics.

In a new paper published in Applied Physics Letters, which is part of a multiyear research effort, a team of scientists from MIT and elsewhere sought to answer key questions about the material’s properties and performance at extremely high temperatures.  

They studied the impact of temperature on the ohmic contacts in a gallium nitride device. Ohmic contacts are key components that connect a semiconductor device with the outside world.

The researchers found that extreme temperatures didn’t cause significant degradation to the gallium nitride material or contacts. They were surprised to see that the contacts remained structurally intact even when held at 500 degrees Celsius for 48 hours.

Understanding how contacts perform at extreme temperatures is an important step toward the group’s next goal of developing high-performance transistors that could operate on the surface of Venus. Such transistors could also be used on Earth in electronics for applications like extracting geothermal energy or monitoring the inside of jet engines.

“Transistors are the heart of most modern electronics, but we didn’t want to jump straight to making a gallium nitride transistor because so much could go wrong. We first wanted to make sure the material and contacts could survive, and figure out how much they change as you increase the temperature. We’ll design our transistor from these basic material building blocks,” says John Niroula, an electrical engineering and computer science (EECS) graduate student and lead author of the paper.

His co-authors include Qingyun Xie PhD ’24; Mengyang Yuan PhD ’22; EECS graduate students Patrick K. Darmawi-Iskandar and Pradyot Yadav; Gillian K. Micale, a graduate student in the Department of Materials Science and Engineering; senior author Tomás Palacios, the Clarence J. LeBel Professor of EECS, director of the Microsystems Technology Laboratories, and a member of the Research Laboratory of Electronics; as well as collaborators Nitul S. Rajput of the Technology Innovation Institute of the United Arab Emirates; Siddharth Rajan of Ohio State University; Yuji Zhao of Rice University; and Nadim Chowdhury of Bangladesh University of Engineering and Technology.

Turning up the heat

While gallium nitride has recently attracted much attention, the material is still decades behind silicon when it comes to scientists’ understanding of how its properties change under different conditions. One such property is resistance, the flow of electrical current through a material.

A device’s overall resistance is inversely proportional to its size. But devices like semiconductors have contacts that connect them to other electronics. Contact resistance, which is caused by these electrical connections, remains fixed no matter the size of the device. Too much contact resistance can lead to higher power dissipation and slower operating frequencies for electronic circuits.

“Especially when you go to smaller dimensions, a device’s performance often ends up being limited by contact resistance. People have a relatively good understanding of contact resistance at room temperature, but no one has really studied what happens when you go all the way up to 500 degrees,” Niroula says.

For their study, the researchers used facilities at MIT.nano to build gallium nitride devices known as transfer length method structures, which are composed of a series of resistors. These devices enable them to measure the resistance of both the material and the contacts.

They added ohmic contacts to these devices using the two most common methods. The first involves depositing metal onto gallium nitride and heating it to 825 degrees Celsius for about 30 seconds, a process called annealing.

The second method involves removing chunks of gallium nitride and using a high-temperature technology to regrow highly doped gallium nitride in its place, a process led by Rajan and his team at Ohio State. The highly doped material contains extra electrons that can contribute to current conduction.

“The regrowth method typically leads to lower contact resistance at room temperature, but we wanted to see if these methods still work well at high temperatures,” Niroula says.

A comprehensive approach

They tested devices in two ways. Their collaborators at Rice University, led by Zhao, conducted short-term tests by placing devices on a hot chuck that reached 500 degrees Celsius and taking immediate resistance measurements.

At MIT, they conducted longer-term experiments by placing devices into a specialized furnace the group previously developed. They left devices inside for up to 72 hours to measure how resistance changes as a function of temperature and time.

Microscopy experts at MIT.nano (Aubrey N. Penn) and the Technology Innovation Institute (Nitul S. Rajput) used state-of-the-art transmission electron microscopes to see how such high temperatures affect gallium nitride and the ohmic contacts at the atomic level.

“We went in thinking the contacts or the gallium nitride material itself would degrade significantly, but we found the opposite. Contacts made with both methods seemed to be remarkably stable,” says Niroula.

While it is difficult to measure resistance at such high temperatures, their results indicate that contact resistance seems to remain constant even at temperatures of 500 degrees, for around 48 hours. And just like at room temperature, the regrowth process led to better performance.

The material did start to degrade after being in the furnace for 48 hours, but the researchers are already working to boost long-term performance. One strategy involves adding protective insulators to keep the material from being directly exposed to the high-temperature environment.

Moving forward, the researchers plan to use what they learned in these experiments to develop high-temperature gallium nitride transistors.

“In our group, we focus on innovative, device-level research to advance the frontiers of microelectronics, while adopting a systematic approach across the hierarchy, from the material level to the circuit level. Here, we have gone all the way down to the material level to understand things in depth. In other words, we have translated device-level advancements to circuit-level impact for high-temperature electronics, through design, modeling and complex fabrication. We are also immensely fortunate to have forged close partnerships with our longtime collaborators in this journey,” Xie says.

This work was funded, in part, by the U.S. Air Force Office of Scientific Research, Lockheed Martin Corporation, the Semiconductor Research Corporation through the U.S. Defense Advanced Research Projects Agency, the U.S. Department of Energy, Intel Corporation, and the Bangladesh University of Engineering and Technology.

Fabrication and microscopy were conducted at MIT.nano, the Semiconductor Epitaxy and Analysis Laboratory at Ohio State University, the Center for Advanced Materials Characterization at the University of Oregon, and the Technology Innovation Institute of the United Arab Emirates.

Consider the dizzying ascent of solar energy in the United States: In the past decade, solar capacity increased nearly 900 percent, with electricity production eight times greater in 2023 than in 2014. The jump from 2022 to 2023 alone was 51 percent, with a record 32 gigawatts (GW) of solar installations coming online. In the past four years, more solar has been added to the grid than any other form of generation. Installed solar now tops 179 GW, enough to power nearly 33 million homes. The U.S. Department of Energy (DOE) is so bullish on the sun that its decarbonization plans envision solar satisfying 45 percent of the nation’s electricity demands by 2050.

But the continued rapid expansion of solar requires advances in technology, notably to improve the efficiency and durability of solar photovoltaic (PV) materials and manufacturing. That’s where Optigon, a three-year-old MIT spinout company, comes in.

“Our goal is to build tools for research and industry that can accelerate the energy transition,” says Dane deQuilettes, the company’s co-founder and chief science officer. “The technology we have developed for solar will enable measurements and analysis of materials as they are being made both in lab and on the manufacturing line, dramatically speeding up the optimization of PV.”

With roots in MIT’s vibrant solar research community, Optigon is poised for a 2024 rollout of technology it believes will drastically pick up the pace of solar power and other clean energy projects.

Beyond silicon

Silicon, the material mainstay of most PV, is limited by the laws of physics in the efficiencies it can achieve converting photons from the sun into electrical energy. Silicon-based solar cells can theoretically reach power conversion levels of just 30 percent, and real-world efficiency levels hover in the low 20s. But beyond the physical limitations of silicon, there is another issue at play for many researchers and the solar industry in the United States and elsewhere: China dominates the silicon PV market, from supply chains to manufacturing.

Scientists are eagerly pursuing alternative materials, either for enhancing silicon’s solar conversion capacity or for replacing silicon altogether.

In the past decade, a family of crystal-structured semiconductors known as perovskites has risen to the fore as a next-generation PV material candidate. Perovskite devices lend themselves to a novel manufacturing process using printing technology that could circumvent the supply chain juggernaut China has built for silicon. Perovskite solar cells can be stacked on each other or layered atop silicon PV, to achieve higher conversion efficiencies. Because perovskite technology is flexible and lightweight, modules can be used on roofs and other structures that cannot support heavier silicon PV, lowering costs and enabling a wider range of building-integrated solar devices.

But these new materials require testing, both during R&D and then on assembly lines, where missing or defective optical, electrical, or dimensional properties in the nano-sized crystal structures can negatively impact the end product.

“The actual measurement and data analysis processes have been really, really slow, because you have to use a bunch of separate tools that are all very manual,” says Optigon co-founder and chief executive officer Anthony Troupe ’21. “We wanted to come up with tools for automating detection of a material’s properties, for determining whether it could make a good or bad solar cell, and then for optimizing it.”

“Our approach packed several non-contact, optical measurements using different types of light sources and detectors into a single system, which together provide a holistic, cross-sectional view of the material,” says Brandon Motes ’21, ME ’22, co-founder and chief technical officer.

“This breakthrough in achieving millisecond timescales for data collection and analysis means we can take research-quality tools and actually put them on a full production system, getting extremely detailed information about products being built at massive, gigawatt scale in real-time,” says Troupe.

This streamlined system takes measurements “in the snap of the fingers, unlike the traditional tools,” says Joseph Berry, director of the US Manufacturing of Advanced Perovskites Consortium and a senior research scientist at the National Renewable Energy Laboratory. “Optigon’s techniques are high precision and allow high throughput, which means they can be used in a lot of contexts where you want rapid feedback and the ability to develop materials very, very quickly.”

According to Berry, Optigon’s technology may give the solar industry not just better materials, but the ability to pump out high-quality PV products at a brisker clip than is currently possible. “If Optigon is successful in deploying their technology, then we can more rapidly develop the materials that we need, manufacturing with the requisite precision again and again,” he says. “This could lead to the next generation of PV modules at a much, much lower cost.”

Measuring makes the difference

With Small Business Innovation Research funding from DOE to commercialize its products and a grant from the Massachusetts Clean Energy Center, Optigon has settled into a space at the climate technology incubator Greentown Labs in Somerville, Massachusetts. Here, the team is preparing for this spring’s launch of its first commercial product, whose genesis lies in MIT’s GridEdge Solar Research Program.

Led by Vladimir Bulović, a professor of electrical engineering and the director of MIT.nano, the GridEdge program was established with funding from the Tata Trusts to develop lightweight, flexible, and inexpensive solar cells for distribution to rural communities around the globe. When deQuilettes joined the group in 2017 as a postdoc, he was tasked with directing the program and building the infrastructure to study and make perovskite solar modules.

“We were trying to understand once we made the material whether or not it was good,” he recalls. “There were no good commercial metrology [the science of measurements] tools for materials beyond silicon, so we started to build our own.” Recognizing the group’s need for greater expertise on the problem, especially in the areas of electrical, software, and mechanical engineering, deQuilettes put a call out for undergraduate researchers to help build metrology tools for new solar materials.

“Forty people inquired, but when I met Brandon and Anthony, something clicked; it was clear we had a complementary skill set,” says deQuilettes. “We started working together, with Anthony coming up with beautiful designs to integrate multiple measurements, and Brandon creating boards to control all of the hardware, including different types of lasers. We started filing multiple patents and that was when we saw it all coming together.”

“We knew from the start that metrology could vastly improve not just materials, but production yields,” says Troupe. Adds deQuilettes, “Our goal was getting to the highest performance orders of magnitude faster than it would ordinarily take, so we developed tools that would not just be useful for research labs but for manufacturing lines to give live feedback on quality.”

The device Optigon designed for industry is the size of a football, “with sensor packages crammed into a tiny form factor, taking measurements as material flows directly underneath,” says Motes. “We have also thought carefully about ways to make interaction with this tool as seamless and, dare I say, as enjoyable as possible, streaming data to both a dashboard an operator can watch and to a custom database.”

Photovoltaics is just the start

The company may have already found its market niche. “A research group paid us to use our in-house prototype because they have such a burning need to get these sorts of measurements,” says Troupe, and according to Motes, “Potential customers ask us if they can buy the system now.” deQuilettes says, “Our hope is that we become the de facto company for doing any sort of characterization metrology in the United States and beyond.”

Challenges lie ahead for Optigon: product launches, full-scale manufacturing, technical assistance, and sales. Greentown Labs offers support, as does MIT’s own rich community of solar researchers and entrepreneurs. But the founders are already thinking about next phases.

“We are not limiting ourselves to the photovoltaics area,” says deQuilettes. “We’re planning on working in other clean energy materials such as batteries and fuel cells.”

That’s because the team wants to make the maximum impact on the climate challenge. “We’ve thought a lot about the potential our tools will have on reducing carbon emissions, and we’ve done a really in-depth analysis looking at how our system can increase production yields of solar panels and other energy technologies, reducing materials and energy wasted in conventional optimization,” deQuilettes says. “If we look across all these sectors, we can expect to offset about 1,000 million metric tons of CO₂ [carbon dioxide] per year in the not-too-distant future.”

The team has written scale into its business plan. “We want to be the key enabler for bringing these new energy technologies to market,” says Motes. “We envision being deployed on every manufacturing line making these types of materials. It’s our goal to walk around and know that if we see a solar panel deployed, there’s a pretty high likelihood that it will be one we measured at some point.”

Perovskites, a broad class of compounds with a particular kind of crystal structure, have long been seen as a promising alternative or supplement to today’s silicon or cadmium telluride solar panels. They could be far more lightweight and inexpensive, and could be coated onto virtually any substrate, including paper or flexible plastic that could be rolled up for easy transport.

In their efficiency at converting sunlight to electricity, perovskites are becoming comparable to silicon, whose manufacture still requires long, complex, and energy-intensive processes. One big remaining drawback is longevity: They tend to break down in a matter of months to years, while silicon solar panels can last more than two decades. And their efficiency over large module areas still lags behind silicon. Now, a team of researchers at MIT and several other institutions has revealed ways to optimize efficiency and better control degradation, by engineering the nanoscale structure of perovskite devices.

The study reveals new insights on how to make high-efficiency perovskite solar cells, and also provides new directions for engineers working to bring these solar cells to the commercial marketplace. The work is described today in the journal Nature Energy, in a paper by Dane deQuilettes, a recent MIT postdoc who is now co-founder and chief science officer of the MIT spinout Optigon, along with MIT professors Vladimir Bulovic and Moungi Bawendi, and 10 others at MIT and in Washington state, the U.K., and Korea.

“Ten years ago, if you had asked us what would be the ultimate solution to the rapid development of solar technologies, the answer would have been something that works as well as silicon but whose manufacturing is much simpler,” Bulovic says. “And before we knew it, the field of perovskite photovoltaics appeared. They were as efficient as silicon, and they were as easy to paint on as it is to paint on a piece of paper. The result was tremendous excitement in the field.”

Nonetheless, “there are some significant technical challenges of handling and managing this material in ways we’ve never done before,” he says. But the promise is so great that many hundreds of researchers around the world have been working on this technology. The new study looks at a very small but key detail: how to “passivate” the material’s surface, changing its properties in such a way that the perovskite no longer degrades so rapidly or loses efficiency.

“The key is identifying the chemistry of the interfaces, the place where the perovskite meets other materials,” Bulovic says, referring to the places where different materials are stacked next to perovskite in order to facilitate the flow of current through the device.

Engineers have developed methods for passivation, for example by using a solution that creates a thin passivating coating. But they’ve lacked a detailed understanding of how this process works — which is essential to make further progress in finding better coatings. The new study “addressed the ability to passivate those interfaces and elucidate the physics and science behind why this passivation works as well as it does,” Bulovic says.

The team used some of the most powerful instruments available at laboratories around the world to observe the interfaces between the perovskite layer and other materials, and how they develop, in unprecedented detail. This close examination of the passivation coating process and its effects resulted in “the clearest roadmap as of yet of what we can do to fine-tune the energy alignment at the interfaces of perovskites and neighboring materials,” and thus improve their overall performance, Bulovic says.

While the bulk of a perovskite material is in the form of a perfectly ordered crystalline lattice of atoms, this order breaks down at the surface. There may be extra atoms sticking out or vacancies where atoms are missing, and these defects cause losses in the material’s efficiency. That’s where the need for passivation comes in.

“This paper is essentially revealing a guidebook for how to tune surfaces, where a lot of these defects are, to make sure that energy is not lost at surfaces,” deQuilettes says. “It’s a really big discovery for the field,” he says. “This is the first paper that demonstrates how to systematically control and engineer surface fields in perovskites.”

The common passivation method is to bathe the surface in a solution of a salt called hexylammonium bromide, a technique developed at MIT several years ago by Jason Jungwan Yoo PhD ’20, who is a co-author of this paper, that led to multiple new world-record efficiencies. By doing that “you form a very thin layer on top of your defective surface, and that thin layer actually passivates a lot of the defects really well,” deQuilettes says. “And then the bromine, which is part of the salt, actually penetrates into the three-dimensional layer in a controllable way.” That penetration helps to prevent electrons from losing energy to defects at the surface.

These two effects, produced by a single processing step, produces the two beneficial changes simultaneously. “It’s really beautiful because usually you need to do that in two steps,” deQuilettes says.

The passivation reduces the energy loss of electrons at the surface after they have been knocked loose by sunlight. These losses reduce the overall efficiency of the conversion of sunlight to electricity, so reducing the losses boosts the net efficiency of the cells.

That could rapidly lead to improvements in the materials’ efficiency in converting sunlight to electricity, he says. The recent efficiency records for a single perovskite layer, several of them set at MIT, have ranged from about 24 to 26 percent, while the maximum theoretical efficiency that could be reached is about 30 percent, according to deQuilettes.

An increase of a few percent may not sound like much, but in the solar photovoltaic industry such improvements are highly sought after. “In the silicon photovoltaic industry, if you’re gaining half of a percent in efficiency, that’s worth hundreds of millions of dollars on the global market,” he says. A recent shift in silicon cell design, essentially adding a thin passivating layer and changing the doping profile, provides an efficiency gain of about half of a percent. As a result, “the whole industry is shifting and rapidly trying to push to get there.” The overall efficiency of silicon solar cells has only seen very small incremental improvements for the last 30 years, he says.

The record efficiencies for perovskites have mostly been set in controlled laboratory settings with small postage-stamp-size samples of the material. “Translating a record efficiency to commercial scale takes a long time,” deQuilettes says. “Another big hope is that with this understanding, people will be able to better engineer large areas to have these passivating effects.”

There are hundreds of different kinds of passivating salts and many different kinds of perovskites, so the basic understanding of the passivation process provided by this new work could help guide researchers to find even better combinations of materials, the researchers suggest. “There are so many different ways you could engineer the materials,” he says.

“I think we are on the doorstep of the first practical demonstrations of perovskites in the commercial applications,” Bulovic says. “And those first applications will be a far cry from what we’ll be able to do a few years from now.” He adds that perovskites “should not be seen as a displacement of silicon photovoltaics. It should be seen as an augmentation — yet another way to bring about more rapid deployment of solar electricity.”

“A lot of progress has been made in the last two years on finding surface treatments that improve perovskite solar cells,” says Michael McGehee, a professor of chemical engineering at the University of Colorado who was not associated with this research. “A lot of the research has been empirical with the mechanisms behind the improvements not being fully understood. This detailed study shows that treatments can not only passivate defects, but can also create a surface field that repels carriers that should be collected at the other side of the device. This understanding might help further improve the interfaces.”

The team included researchers at the Korea Research Institute of Chemical Technology, Cambridge University, the University of Washington in Seattle, and Sungkyunkwan University in Korea. The work was supported by the Tata Trust, the MIT Institute for Soldier Nanotechnologies, the U.S. Department of Energy, and the U.S. National Science Foundation.

The scorching surface of Venus, where temperatures can climb to 480 degrees Celsius (hot enough to melt lead), is an inhospitable place for humans and machines alike. One reason scientists have not yet been able to send a rover to the planet’s surface is because silicon-based electronics can’t operate in such extreme temperatures for an extended period of time.

For high-temperature applications like Venus exploration, researchers have recently turned to gallium nitride, a unique material that can withstand temperatures of 500 degrees or more.

The material is already used in some terrestrial electronics, like phone chargers and cell phone towers, but scientists don’t have a good grasp of how gallium nitride devices would behave at temperatures beyond 300 degrees, which is the operational limit of conventional silicon electronics.

In a new paper published in Applied Physics Letters, which is part of a multiyear research effort, a team of scientists from MIT and elsewhere sought to answer key questions about the material’s properties and performance at extremely high temperatures.  

They studied the impact of temperature on the ohmic contacts in a gallium nitride device. Ohmic contacts are key components that connect a semiconductor device with the outside world.

The researchers found that extreme temperatures didn’t cause significant degradation to the gallium nitride material or contacts. They were surprised to see that the contacts remained structurally intact even when held at 500 degrees Celsius for 48 hours.

Understanding how contacts perform at extreme temperatures is an important step toward the group’s next goal of developing high-performance transistors that could operate on the surface of Venus. Such transistors could also be used on Earth in electronics for applications like extracting geothermal energy or monitoring the inside of jet engines.

“Transistors are the heart of most modern electronics, but we didn’t want to jump straight to making a gallium nitride transistor because so much could go wrong. We first wanted to make sure the material and contacts could survive, and figure out how much they change as you increase the temperature. We’ll design our transistor from these basic material building blocks,” says John Niroula, an electrical engineering and computer science (EECS) graduate student and lead author of the paper.

His co-authors include Qingyun Xie PhD ’24; Mengyang Yuan PhD ’22; EECS graduate students Patrick K. Darmawi-Iskandar and Pradyot Yadav; Gillian K. Micale, a graduate student in the Department of Materials Science and Engineering; senior author Tomás Palacios, the Clarence J. LeBel Professor of EECS, director of the Microsystems Technology Laboratories, and a member of the Research Laboratory of Electronics; as well as collaborators Nitul S. Rajput of the Technology Innovation Institute of the United Arab Emirates; Siddharth Rajan of Ohio State University; Yuji Zhao of Rice University; and Nadim Chowdhury of Bangladesh University of Engineering and Technology.

Turning up the heat

While gallium nitride has recently attracted much attention, the material is still decades behind silicon when it comes to scientists’ understanding of how its properties change under different conditions. One such property is resistance, the flow of electrical current through a material.

A device’s overall resistance is inversely proportional to its size. But devices like semiconductors have contacts that connect them to other electronics. Contact resistance, which is caused by these electrical connections, remains fixed no matter the size of the device. Too much contact resistance can lead to higher power dissipation and slower operating frequencies for electronic circuits.

“Especially when you go to smaller dimensions, a device’s performance often ends up being limited by contact resistance. People have a relatively good understanding of contact resistance at room temperature, but no one has really studied what happens when you go all the way up to 500 degrees,” Niroula says.

For their study, the researchers used facilities at MIT.nano to build gallium nitride devices known as transfer length method structures, which are composed of a series of resistors. These devices enable them to measure the resistance of both the material and the contacts.

They added ohmic contacts to these devices using the two most common methods. The first involves depositing metal onto gallium nitride and heating it to 825 degrees Celsius for about 30 seconds, a process called annealing.

The second method involves removing chunks of gallium nitride and using a high-temperature technology to regrow highly doped gallium nitride in its place, a process led by Rajan and his team at Ohio State. The highly doped material contains extra electrons that can contribute to current conduction.

“The regrowth method typically leads to lower contact resistance at room temperature, but we wanted to see if these methods still work well at high temperatures,” Niroula says.

A comprehensive approach

They tested devices in two ways. Their collaborators at Rice University, led by Zhao, conducted short-term tests by placing devices on a hot chuck that reached 500 degrees Celsius and taking immediate resistance measurements.

At MIT, they conducted longer-term experiments by placing devices into a specialized furnace the group previously developed. They left devices inside for up to 72 hours to measure how resistance changes as a function of temperature and time.

Microscopy experts at MIT.nano (Aubrey N. Penn) and the Technology Innovation Institute (Nitul S. Rajput) used state-of-the-art transmission electron microscopes to see how such high temperatures affect gallium nitride and the ohmic contacts at the atomic level.

“We went in thinking the contacts or the gallium nitride material itself would degrade significantly, but we found the opposite. Contacts made with both methods seemed to be remarkably stable,” says Niroula.

While it is difficult to measure resistance at such high temperatures, their results indicate that contact resistance seems to remain constant even at temperatures of 500 degrees, for around 48 hours. And just like at room temperature, the regrowth process led to better performance.

The material did start to degrade after being in the furnace for 48 hours, but the researchers are already working to boost long-term performance. One strategy involves adding protective insulators to keep the material from being directly exposed to the high-temperature environment.

Moving forward, the researchers plan to use what they learned in these experiments to develop high-temperature gallium nitride transistors.

“In our group, we focus on innovative, device-level research to advance the frontiers of microelectronics, while adopting a systematic approach across the hierarchy, from the material level to the circuit level. Here, we have gone all the way down to the material level to understand things in depth. In other words, we have translated device-level advancements to circuit-level impact for high-temperature electronics, through design, modeling and complex fabrication. We are also immensely fortunate to have forged close partnerships with our longtime collaborators in this journey,” Xie says.

This work was funded, in part, by the U.S. Air Force Office of Scientific Research, Lockheed Martin Corporation, the Semiconductor Research Corporation through the U.S. Defense Advanced Research Projects Agency, the U.S. Department of Energy, Intel Corporation, and the Bangladesh University of Engineering and Technology.

Fabrication and microscopy were conducted at MIT.nano, the Semiconductor Epitaxy and Analysis Laboratory at Ohio State University, the Center for Advanced Materials Characterization at the University of Oregon, and the Technology Innovation Institute of the United Arab Emirates.

Consider the dizzying ascent of solar energy in the United States: In the past decade, solar capacity increased nearly 900 percent, with electricity production eight times greater in 2023 than in 2014. The jump from 2022 to 2023 alone was 51 percent, with a record 32 gigawatts (GW) of solar installations coming online. In the past four years, more solar has been added to the grid than any other form of generation. Installed solar now tops 179 GW, enough to power nearly 33 million homes. The U.S. Department of Energy (DOE) is so bullish on the sun that its decarbonization plans envision solar satisfying 45 percent of the nation’s electricity demands by 2050.

But the continued rapid expansion of solar requires advances in technology, notably to improve the efficiency and durability of solar photovoltaic (PV) materials and manufacturing. That’s where Optigon, a three-year-old MIT spinout company, comes in.

“Our goal is to build tools for research and industry that can accelerate the energy transition,” says Dane deQuilettes, the company’s co-founder and chief science officer. “The technology we have developed for solar will enable measurements and analysis of materials as they are being made both in lab and on the manufacturing line, dramatically speeding up the optimization of PV.”

With roots in MIT’s vibrant solar research community, Optigon is poised for a 2024 rollout of technology it believes will drastically pick up the pace of solar power and other clean energy projects.

Beyond silicon

Silicon, the material mainstay of most PV, is limited by the laws of physics in the efficiencies it can achieve converting photons from the sun into electrical energy. Silicon-based solar cells can theoretically reach power conversion levels of just 30 percent, and real-world efficiency levels hover in the low 20s. But beyond the physical limitations of silicon, there is another issue at play for many researchers and the solar industry in the United States and elsewhere: China dominates the silicon PV market, from supply chains to manufacturing.

Scientists are eagerly pursuing alternative materials, either for enhancing silicon’s solar conversion capacity or for replacing silicon altogether.

In the past decade, a family of crystal-structured semiconductors known as perovskites has risen to the fore as a next-generation PV material candidate. Perovskite devices lend themselves to a novel manufacturing process using printing technology that could circumvent the supply chain juggernaut China has built for silicon. Perovskite solar cells can be stacked on each other or layered atop silicon PV, to achieve higher conversion efficiencies. Because perovskite technology is flexible and lightweight, modules can be used on roofs and other structures that cannot support heavier silicon PV, lowering costs and enabling a wider range of building-integrated solar devices.

But these new materials require testing, both during R&D and then on assembly lines, where missing or defective optical, electrical, or dimensional properties in the nano-sized crystal structures can negatively impact the end product.

“The actual measurement and data analysis processes have been really, really slow, because you have to use a bunch of separate tools that are all very manual,” says Optigon co-founder and chief executive officer Anthony Troupe ’21. “We wanted to come up with tools for automating detection of a material’s properties, for determining whether it could make a good or bad solar cell, and then for optimizing it.”

“Our approach packed several non-contact, optical measurements using different types of light sources and detectors into a single system, which together provide a holistic, cross-sectional view of the material,” says Brandon Motes ’21, ME ’22, co-founder and chief technical officer.

“This breakthrough in achieving millisecond timescales for data collection and analysis means we can take research-quality tools and actually put them on a full production system, getting extremely detailed information about products being built at massive, gigawatt scale in real-time,” says Troupe.

This streamlined system takes measurements “in the snap of the fingers, unlike the traditional tools,” says Joseph Berry, director of the US Manufacturing of Advanced Perovskites Consortium and a senior research scientist at the National Renewable Energy Laboratory. “Optigon’s techniques are high precision and allow high throughput, which means they can be used in a lot of contexts where you want rapid feedback and the ability to develop materials very, very quickly.”

According to Berry, Optigon’s technology may give the solar industry not just better materials, but the ability to pump out high-quality PV products at a brisker clip than is currently possible. “If Optigon is successful in deploying their technology, then we can more rapidly develop the materials that we need, manufacturing with the requisite precision again and again,” he says. “This could lead to the next generation of PV modules at a much, much lower cost.”

Measuring makes the difference

With Small Business Innovation Research funding from DOE to commercialize its products and a grant from the Massachusetts Clean Energy Center, Optigon has settled into a space at the climate technology incubator Greentown Labs in Somerville, Massachusetts. Here, the team is preparing for this spring’s launch of its first commercial product, whose genesis lies in MIT’s GridEdge Solar Research Program.

Led by Vladimir Bulović, a professor of electrical engineering and the director of MIT.nano, the GridEdge program was established with funding from the Tata Trusts to develop lightweight, flexible, and inexpensive solar cells for distribution to rural communities around the globe. When deQuilettes joined the group in 2017 as a postdoc, he was tasked with directing the program and building the infrastructure to study and make perovskite solar modules.

“We were trying to understand once we made the material whether or not it was good,” he recalls. “There were no good commercial metrology [the science of measurements] tools for materials beyond silicon, so we started to build our own.” Recognizing the group’s need for greater expertise on the problem, especially in the areas of electrical, software, and mechanical engineering, deQuilettes put a call out for undergraduate researchers to help build metrology tools for new solar materials.

“Forty people inquired, but when I met Brandon and Anthony, something clicked; it was clear we had a complementary skill set,” says deQuilettes. “We started working together, with Anthony coming up with beautiful designs to integrate multiple measurements, and Brandon creating boards to control all of the hardware, including different types of lasers. We started filing multiple patents and that was when we saw it all coming together.”

“We knew from the start that metrology could vastly improve not just materials, but production yields,” says Troupe. Adds deQuilettes, “Our goal was getting to the highest performance orders of magnitude faster than it would ordinarily take, so we developed tools that would not just be useful for research labs but for manufacturing lines to give live feedback on quality.”

The device Optigon designed for industry is the size of a football, “with sensor packages crammed into a tiny form factor, taking measurements as material flows directly underneath,” says Motes. “We have also thought carefully about ways to make interaction with this tool as seamless and, dare I say, as enjoyable as possible, streaming data to both a dashboard an operator can watch and to a custom database.”

Photovoltaics is just the start

The company may have already found its market niche. “A research group paid us to use our in-house prototype because they have such a burning need to get these sorts of measurements,” says Troupe, and according to Motes, “Potential customers ask us if they can buy the system now.” deQuilettes says, “Our hope is that we become the de facto company for doing any sort of characterization metrology in the United States and beyond.”

Challenges lie ahead for Optigon: product launches, full-scale manufacturing, technical assistance, and sales. Greentown Labs offers support, as does MIT’s own rich community of solar researchers and entrepreneurs. But the founders are already thinking about next phases.

“We are not limiting ourselves to the photovoltaics area,” says deQuilettes. “We’re planning on working in other clean energy materials such as batteries and fuel cells.”

That’s because the team wants to make the maximum impact on the climate challenge. “We’ve thought a lot about the potential our tools will have on reducing carbon emissions, and we’ve done a really in-depth analysis looking at how our system can increase production yields of solar panels and other energy technologies, reducing materials and energy wasted in conventional optimization,” deQuilettes says. “If we look across all these sectors, we can expect to offset about 1,000 million metric tons of CO₂ [carbon dioxide] per year in the not-too-distant future.”

The team has written scale into its business plan. “We want to be the key enabler for bringing these new energy technologies to market,” says Motes. “We envision being deployed on every manufacturing line making these types of materials. It’s our goal to walk around and know that if we see a solar panel deployed, there’s a pretty high likelihood that it will be one we measured at some point.”

Perovskites, a broad class of compounds with a particular kind of crystal structure, have long been seen as a promising alternative or supplement to today’s silicon or cadmium telluride solar panels. They could be far more lightweight and inexpensive, and could be coated onto virtually any substrate, including paper or flexible plastic that could be rolled up for easy transport.

In their efficiency at converting sunlight to electricity, perovskites are becoming comparable to silicon, whose manufacture still requires long, complex, and energy-intensive processes. One big remaining drawback is longevity: They tend to break down in a matter of months to years, while silicon solar panels can last more than two decades. And their efficiency over large module areas still lags behind silicon. Now, a team of researchers at MIT and several other institutions has revealed ways to optimize efficiency and better control degradation, by engineering the nanoscale structure of perovskite devices.

The study reveals new insights on how to make high-efficiency perovskite solar cells, and also provides new directions for engineers working to bring these solar cells to the commercial marketplace. The work is described today in the journal Nature Energy, in a paper by Dane deQuilettes, a recent MIT postdoc who is now co-founder and chief science officer of the MIT spinout Optigon, along with MIT professors Vladimir Bulovic and Moungi Bawendi, and 10 others at MIT and in Washington state, the U.K., and Korea.

“Ten years ago, if you had asked us what would be the ultimate solution to the rapid development of solar technologies, the answer would have been something that works as well as silicon but whose manufacturing is much simpler,” Bulovic says. “And before we knew it, the field of perovskite photovoltaics appeared. They were as efficient as silicon, and they were as easy to paint on as it is to paint on a piece of paper. The result was tremendous excitement in the field.”

Nonetheless, “there are some significant technical challenges of handling and managing this material in ways we’ve never done before,” he says. But the promise is so great that many hundreds of researchers around the world have been working on this technology. The new study looks at a very small but key detail: how to “passivate” the material’s surface, changing its properties in such a way that the perovskite no longer degrades so rapidly or loses efficiency.

“The key is identifying the chemistry of the interfaces, the place where the perovskite meets other materials,” Bulovic says, referring to the places where different materials are stacked next to perovskite in order to facilitate the flow of current through the device.

Engineers have developed methods for passivation, for example by using a solution that creates a thin passivating coating. But they’ve lacked a detailed understanding of how this process works — which is essential to make further progress in finding better coatings. The new study “addressed the ability to passivate those interfaces and elucidate the physics and science behind why this passivation works as well as it does,” Bulovic says.

The team used some of the most powerful instruments available at laboratories around the world to observe the interfaces between the perovskite layer and other materials, and how they develop, in unprecedented detail. This close examination of the passivation coating process and its effects resulted in “the clearest roadmap as of yet of what we can do to fine-tune the energy alignment at the interfaces of perovskites and neighboring materials,” and thus improve their overall performance, Bulovic says.

While the bulk of a perovskite material is in the form of a perfectly ordered crystalline lattice of atoms, this order breaks down at the surface. There may be extra atoms sticking out or vacancies where atoms are missing, and these defects cause losses in the material’s efficiency. That’s where the need for passivation comes in.

“This paper is essentially revealing a guidebook for how to tune surfaces, where a lot of these defects are, to make sure that energy is not lost at surfaces,” deQuilettes says. “It’s a really big discovery for the field,” he says. “This is the first paper that demonstrates how to systematically control and engineer surface fields in perovskites.”

The common passivation method is to bathe the surface in a solution of a salt called hexylammonium bromide, a technique developed at MIT several years ago by Jason Jungwan Yoo PhD ’20, who is a co-author of this paper, that led to multiple new world-record efficiencies. By doing that “you form a very thin layer on top of your defective surface, and that thin layer actually passivates a lot of the defects really well,” deQuilettes says. “And then the bromine, which is part of the salt, actually penetrates into the three-dimensional layer in a controllable way.” That penetration helps to prevent electrons from losing energy to defects at the surface.

These two effects, produced by a single processing step, produces the two beneficial changes simultaneously. “It’s really beautiful because usually you need to do that in two steps,” deQuilettes says.

The passivation reduces the energy loss of electrons at the surface after they have been knocked loose by sunlight. These losses reduce the overall efficiency of the conversion of sunlight to electricity, so reducing the losses boosts the net efficiency of the cells.

That could rapidly lead to improvements in the materials’ efficiency in converting sunlight to electricity, he says. The recent efficiency records for a single perovskite layer, several of them set at MIT, have ranged from about 24 to 26 percent, while the maximum theoretical efficiency that could be reached is about 30 percent, according to deQuilettes.

An increase of a few percent may not sound like much, but in the solar photovoltaic industry such improvements are highly sought after. “In the silicon photovoltaic industry, if you’re gaining half of a percent in efficiency, that’s worth hundreds of millions of dollars on the global market,” he says. A recent shift in silicon cell design, essentially adding a thin passivating layer and changing the doping profile, provides an efficiency gain of about half of a percent. As a result, “the whole industry is shifting and rapidly trying to push to get there.” The overall efficiency of silicon solar cells has only seen very small incremental improvements for the last 30 years, he says.

The record efficiencies for perovskites have mostly been set in controlled laboratory settings with small postage-stamp-size samples of the material. “Translating a record efficiency to commercial scale takes a long time,” deQuilettes says. “Another big hope is that with this understanding, people will be able to better engineer large areas to have these passivating effects.”

There are hundreds of different kinds of passivating salts and many different kinds of perovskites, so the basic understanding of the passivation process provided by this new work could help guide researchers to find even better combinations of materials, the researchers suggest. “There are so many different ways you could engineer the materials,” he says.

“I think we are on the doorstep of the first practical demonstrations of perovskites in the commercial applications,” Bulovic says. “And those first applications will be a far cry from what we’ll be able to do a few years from now.” He adds that perovskites “should not be seen as a displacement of silicon photovoltaics. It should be seen as an augmentation — yet another way to bring about more rapid deployment of solar electricity.”

“A lot of progress has been made in the last two years on finding surface treatments that improve perovskite solar cells,” says Michael McGehee, a professor of chemical engineering at the University of Colorado who was not associated with this research. “A lot of the research has been empirical with the mechanisms behind the improvements not being fully understood. This detailed study shows that treatments can not only passivate defects, but can also create a surface field that repels carriers that should be collected at the other side of the device. This understanding might help further improve the interfaces.”

The team included researchers at the Korea Research Institute of Chemical Technology, Cambridge University, the University of Washington in Seattle, and Sungkyunkwan University in Korea. The work was supported by the Tata Trust, the MIT Institute for Soldier Nanotechnologies, the U.S. Department of Energy, and the U.S. National Science Foundation.

VinFast, a Vietnamese automaker that builds electric vehicles, announced in July that it would not begin production at its North Carolina plant for another four years. While the news is certainly a setback, the disappointment is compounded by the fact that the state is trying to bulldoze a number of private homes, and a church, to make the project happen.

In March 2022, North Carolina Gov. Roy Cooper announced that VinFast would build its first North American plant in Chatham County. The company would spend $4 billion and create 7,500 jobs, with production from the completed factory set to begin in July 2024. At its peak, the facility would be capable of producing 150,000 vehicles per year.

In exchange, North Carolina lawmakers agreed to give the company $1.25 billion in incentives, including $450 million for infrastructure, including "roadway improvements" and building out the water and sewer capacity; $400 million from the county; and a $316 million state grant paid out over 32 years, linked to the company's job creation promises. In effect, North Carolina taxpayers would be financing over 30 percent of the project.

President Joe Biden called the project "the latest example of my economic strategy at work." CNBC lauded the state's Democratic governor and Republican Legislature for "managing to put aside their very deep political divisions to boost business and the economy" when it named North Carolina America's Top State for Business.

But within two years, the deal was on shaky ground. The company announced in March 2023 that it would not be able to begin production at the factory until at least 2025 "because we need more time to complete administrative procedures," according to a company spokesperson.

Then in July 2024, in a press release about manufacturing output in the previous quarter, VinFast announced that it had "made the strategic decision to adjust the timeline for the launch of its North Carolina manufacturing facility, which is now expected to begin production in 2028," in order to "optimize its capital allocation and manage its short-term spending more effectively."

While this is disappointing news for many—company executives, shareholders, North Carolina state officials—it's worse for residents in the area.

Many of the state and county incentives are dependent upon VinFast meeting certain metrics: While the state doled out $125 million to reimburse the company for site preparation costs, it can claw back that entire amount if VinFast fails to hire at least 3,875 people—just over 50 percent of the required total. There are further clawback provisions if it doesn't hire at least 6,000 people and doesn't invest at least $2 billion into the project.

But even if the deal falls apart and the state gets its money back, some things can't be undone. As part of the deal, the North Carolina Department of Transportation (NCDOT) would conduct "roadway improvements" at the future site of the facility. As detailed in an August 2022 project overview, "private property is needed to construct the improvements proposed by the roadway project." And while the NCDOT "works to minimize impacts such as the number of homes and businesses displaced by a road project, some impacts are unavoidable."

In total, the state expected that the roadwork would "impact" five businesses, 27 homes, and Merry Oaks Baptist Church, which had stood since 1888. This meant the state was authorized to purchase the properties from the owners—or if the owners refused to sell, the state could simply take the properties through eminent domain.

Eminent domain, authorized by the Takings Clause of the Fifth Amendment, allows government entities to seize private property for public use, as long as the owner receives "just compensation." Of course, the only thing that separates this from a normal real estate transaction is that the use of eminent domain implies that the property owner did not want to sell but was forced to anyway.

While an electric car factory does not qualify as a "public use," the state is planning to bulldoze the houses, businesses, and church to make way for a new roadway interchange that will accommodate traffic to and from the site. Of course, under the U.S. Supreme Court's 2005 decision in Kelo v. New London, the state would also have been justified to seize property to give to a purely private party, with Justice John Paul Stevens writing that "there is no basis for exempting economic development from our traditionally broad understanding of public purpose."

In fact, that seems to be just what happened: In July, after VinFast announced its latest delay, the Raleigh News & Observer reported that so far the state had spent $96 million—nearly all of it on site preparation and infrastructure—and purchased four homes, with negotiations ongoing with other homeowners and two businesses. And sadly, "North Carolina has acquired two businesses and Merry Oaks Baptist Church through eminent domain, meaning negotiations fell short and the state took over the land after paying the previous owners fair market values assessed by a state-approved appraiser."

In July 2023, VinFast offered to donate up to three acres of land from its 2,000-acre parcel to Merry Oaks Baptist Church so the congregation could relocate. But a better solution would have been for VinFast to simply shoulder the burden of development in the first place, first by footing the bill for the project itself and then by obtaining land where the government did not forcibly remove any obstacles in the way.

The post VinFast Delays Production After North Carolina Seizes Property for Factory Site appeared first on Reason.com.

The scorching surface of Venus, where temperatures can climb to 480 degrees Celsius (hot enough to melt lead), is an inhospitable place for humans and machines alike. One reason scientists have not yet been able to send a rover to the planet’s surface is because silicon-based electronics can’t operate in such extreme temperatures for an extended period of time.

For high-temperature applications like Venus exploration, researchers have recently turned to gallium nitride, a unique material that can withstand temperatures of 500 degrees or more.

The material is already used in some terrestrial electronics, like phone chargers and cell phone towers, but scientists don’t have a good grasp of how gallium nitride devices would behave at temperatures beyond 300 degrees, which is the operational limit of conventional silicon electronics.

In a new paper published in Applied Physics Letters, which is part of a multiyear research effort, a team of scientists from MIT and elsewhere sought to answer key questions about the material’s properties and performance at extremely high temperatures.  

They studied the impact of temperature on the ohmic contacts in a gallium nitride device. Ohmic contacts are key components that connect a semiconductor device with the outside world.

The researchers found that extreme temperatures didn’t cause significant degradation to the gallium nitride material or contacts. They were surprised to see that the contacts remained structurally intact even when held at 500 degrees Celsius for 48 hours.

Understanding how contacts perform at extreme temperatures is an important step toward the group’s next goal of developing high-performance transistors that could operate on the surface of Venus. Such transistors could also be used on Earth in electronics for applications like extracting geothermal energy or monitoring the inside of jet engines.

“Transistors are the heart of most modern electronics, but we didn’t want to jump straight to making a gallium nitride transistor because so much could go wrong. We first wanted to make sure the material and contacts could survive, and figure out how much they change as you increase the temperature. We’ll design our transistor from these basic material building blocks,” says John Niroula, an electrical engineering and computer science (EECS) graduate student and lead author of the paper.

His co-authors include Qingyun Xie PhD ’24; Mengyang Yuan PhD ’22; EECS graduate students Patrick K. Darmawi-Iskandar and Pradyot Yadav; Gillian K. Micale, a graduate student in the Department of Materials Science and Engineering; senior author Tomás Palacios, the Clarence J. LeBel Professor of EECS, director of the Microsystems Technology Laboratories, and a member of the Research Laboratory of Electronics; as well as collaborators Nitul S. Rajput of the Technology Innovation Institute of the United Arab Emirates; Siddharth Rajan of Ohio State University; Yuji Zhao of Rice University; and Nadim Chowdhury of Bangladesh University of Engineering and Technology.

Turning up the heat

While gallium nitride has recently attracted much attention, the material is still decades behind silicon when it comes to scientists’ understanding of how its properties change under different conditions. One such property is resistance, the flow of electrical current through a material.

A device’s overall resistance is inversely proportional to its size. But devices like semiconductors have contacts that connect them to other electronics. Contact resistance, which is caused by these electrical connections, remains fixed no matter the size of the device. Too much contact resistance can lead to higher power dissipation and slower operating frequencies for electronic circuits.

“Especially when you go to smaller dimensions, a device’s performance often ends up being limited by contact resistance. People have a relatively good understanding of contact resistance at room temperature, but no one has really studied what happens when you go all the way up to 500 degrees,” Niroula says.

For their study, the researchers used facilities at MIT.nano to build gallium nitride devices known as transfer length method structures, which are composed of a series of resistors. These devices enable them to measure the resistance of both the material and the contacts.

They added ohmic contacts to these devices using the two most common methods. The first involves depositing metal onto gallium nitride and heating it to 825 degrees Celsius for about 30 seconds, a process called annealing.

The second method involves removing chunks of gallium nitride and using a high-temperature technology to regrow highly doped gallium nitride in its place, a process led by Rajan and his team at Ohio State. The highly doped material contains extra electrons that can contribute to current conduction.

“The regrowth method typically leads to lower contact resistance at room temperature, but we wanted to see if these methods still work well at high temperatures,” Niroula says.

A comprehensive approach

They tested devices in two ways. Their collaborators at Rice University, led by Zhao, conducted short-term tests by placing devices on a hot chuck that reached 500 degrees Celsius and taking immediate resistance measurements.

At MIT, they conducted longer-term experiments by placing devices into a specialized furnace the group previously developed. They left devices inside for up to 72 hours to measure how resistance changes as a function of temperature and time.

Microscopy experts at MIT.nano (Aubrey N. Penn) and the Technology Innovation Institute (Nitul S. Rajput) used state-of-the-art transmission electron microscopes to see how such high temperatures affect gallium nitride and the ohmic contacts at the atomic level.

“We went in thinking the contacts or the gallium nitride material itself would degrade significantly, but we found the opposite. Contacts made with both methods seemed to be remarkably stable,” says Niroula.

While it is difficult to measure resistance at such high temperatures, their results indicate that contact resistance seems to remain constant even at temperatures of 500 degrees, for around 48 hours. And just like at room temperature, the regrowth process led to better performance.

The material did start to degrade after being in the furnace for 48 hours, but the researchers are already working to boost long-term performance. One strategy involves adding protective insulators to keep the material from being directly exposed to the high-temperature environment.

Moving forward, the researchers plan to use what they learned in these experiments to develop high-temperature gallium nitride transistors.

“In our group, we focus on innovative, device-level research to advance the frontiers of microelectronics, while adopting a systematic approach across the hierarchy, from the material level to the circuit level. Here, we have gone all the way down to the material level to understand things in depth. In other words, we have translated device-level advancements to circuit-level impact for high-temperature electronics, through design, modeling and complex fabrication. We are also immensely fortunate to have forged close partnerships with our longtime collaborators in this journey,” Xie says.

This work was funded, in part, by the U.S. Air Force Office of Scientific Research, Lockheed Martin Corporation, the Semiconductor Research Corporation through the U.S. Defense Advanced Research Projects Agency, the U.S. Department of Energy, Intel Corporation, and the Bangladesh University of Engineering and Technology.

Fabrication and microscopy were conducted at MIT.nano, the Semiconductor Epitaxy and Analysis Laboratory at Ohio State University, the Center for Advanced Materials Characterization at the University of Oregon, and the Technology Innovation Institute of the United Arab Emirates.

Consider the dizzying ascent of solar energy in the United States: In the past decade, solar capacity increased nearly 900 percent, with electricity production eight times greater in 2023 than in 2014. The jump from 2022 to 2023 alone was 51 percent, with a record 32 gigawatts (GW) of solar installations coming online. In the past four years, more solar has been added to the grid than any other form of generation. Installed solar now tops 179 GW, enough to power nearly 33 million homes. The U.S. Department of Energy (DOE) is so bullish on the sun that its decarbonization plans envision solar satisfying 45 percent of the nation’s electricity demands by 2050.

But the continued rapid expansion of solar requires advances in technology, notably to improve the efficiency and durability of solar photovoltaic (PV) materials and manufacturing. That’s where Optigon, a three-year-old MIT spinout company, comes in.

“Our goal is to build tools for research and industry that can accelerate the energy transition,” says Dane deQuilettes, the company’s co-founder and chief science officer. “The technology we have developed for solar will enable measurements and analysis of materials as they are being made both in lab and on the manufacturing line, dramatically speeding up the optimization of PV.”

With roots in MIT’s vibrant solar research community, Optigon is poised for a 2024 rollout of technology it believes will drastically pick up the pace of solar power and other clean energy projects.

Beyond silicon

Silicon, the material mainstay of most PV, is limited by the laws of physics in the efficiencies it can achieve converting photons from the sun into electrical energy. Silicon-based solar cells can theoretically reach power conversion levels of just 30 percent, and real-world efficiency levels hover in the low 20s. But beyond the physical limitations of silicon, there is another issue at play for many researchers and the solar industry in the United States and elsewhere: China dominates the silicon PV market, from supply chains to manufacturing.

Scientists are eagerly pursuing alternative materials, either for enhancing silicon’s solar conversion capacity or for replacing silicon altogether.

In the past decade, a family of crystal-structured semiconductors known as perovskites has risen to the fore as a next-generation PV material candidate. Perovskite devices lend themselves to a novel manufacturing process using printing technology that could circumvent the supply chain juggernaut China has built for silicon. Perovskite solar cells can be stacked on each other or layered atop silicon PV, to achieve higher conversion efficiencies. Because perovskite technology is flexible and lightweight, modules can be used on roofs and other structures that cannot support heavier silicon PV, lowering costs and enabling a wider range of building-integrated solar devices.

But these new materials require testing, both during R&D and then on assembly lines, where missing or defective optical, electrical, or dimensional properties in the nano-sized crystal structures can negatively impact the end product.

“The actual measurement and data analysis processes have been really, really slow, because you have to use a bunch of separate tools that are all very manual,” says Optigon co-founder and chief executive officer Anthony Troupe ’21. “We wanted to come up with tools for automating detection of a material’s properties, for determining whether it could make a good or bad solar cell, and then for optimizing it.”

“Our approach packed several non-contact, optical measurements using different types of light sources and detectors into a single system, which together provide a holistic, cross-sectional view of the material,” says Brandon Motes ’21, ME ’22, co-founder and chief technical officer.

“This breakthrough in achieving millisecond timescales for data collection and analysis means we can take research-quality tools and actually put them on a full production system, getting extremely detailed information about products being built at massive, gigawatt scale in real-time,” says Troupe.

This streamlined system takes measurements “in the snap of the fingers, unlike the traditional tools,” says Joseph Berry, director of the US Manufacturing of Advanced Perovskites Consortium and a senior research scientist at the National Renewable Energy Laboratory. “Optigon’s techniques are high precision and allow high throughput, which means they can be used in a lot of contexts where you want rapid feedback and the ability to develop materials very, very quickly.”

According to Berry, Optigon’s technology may give the solar industry not just better materials, but the ability to pump out high-quality PV products at a brisker clip than is currently possible. “If Optigon is successful in deploying their technology, then we can more rapidly develop the materials that we need, manufacturing with the requisite precision again and again,” he says. “This could lead to the next generation of PV modules at a much, much lower cost.”

Measuring makes the difference

With Small Business Innovation Research funding from DOE to commercialize its products and a grant from the Massachusetts Clean Energy Center, Optigon has settled into a space at the climate technology incubator Greentown Labs in Somerville, Massachusetts. Here, the team is preparing for this spring’s launch of its first commercial product, whose genesis lies in MIT’s GridEdge Solar Research Program.

Led by Vladimir Bulović, a professor of electrical engineering and the director of MIT.nano, the GridEdge program was established with funding from the Tata Trusts to develop lightweight, flexible, and inexpensive solar cells for distribution to rural communities around the globe. When deQuilettes joined the group in 2017 as a postdoc, he was tasked with directing the program and building the infrastructure to study and make perovskite solar modules.

“We were trying to understand once we made the material whether or not it was good,” he recalls. “There were no good commercial metrology [the science of measurements] tools for materials beyond silicon, so we started to build our own.” Recognizing the group’s need for greater expertise on the problem, especially in the areas of electrical, software, and mechanical engineering, deQuilettes put a call out for undergraduate researchers to help build metrology tools for new solar materials.

“Forty people inquired, but when I met Brandon and Anthony, something clicked; it was clear we had a complementary skill set,” says deQuilettes. “We started working together, with Anthony coming up with beautiful designs to integrate multiple measurements, and Brandon creating boards to control all of the hardware, including different types of lasers. We started filing multiple patents and that was when we saw it all coming together.”

“We knew from the start that metrology could vastly improve not just materials, but production yields,” says Troupe. Adds deQuilettes, “Our goal was getting to the highest performance orders of magnitude faster than it would ordinarily take, so we developed tools that would not just be useful for research labs but for manufacturing lines to give live feedback on quality.”

The device Optigon designed for industry is the size of a football, “with sensor packages crammed into a tiny form factor, taking measurements as material flows directly underneath,” says Motes. “We have also thought carefully about ways to make interaction with this tool as seamless and, dare I say, as enjoyable as possible, streaming data to both a dashboard an operator can watch and to a custom database.”

Photovoltaics is just the start

The company may have already found its market niche. “A research group paid us to use our in-house prototype because they have such a burning need to get these sorts of measurements,” says Troupe, and according to Motes, “Potential customers ask us if they can buy the system now.” deQuilettes says, “Our hope is that we become the de facto company for doing any sort of characterization metrology in the United States and beyond.”

Challenges lie ahead for Optigon: product launches, full-scale manufacturing, technical assistance, and sales. Greentown Labs offers support, as does MIT’s own rich community of solar researchers and entrepreneurs. But the founders are already thinking about next phases.

“We are not limiting ourselves to the photovoltaics area,” says deQuilettes. “We’re planning on working in other clean energy materials such as batteries and fuel cells.”

That’s because the team wants to make the maximum impact on the climate challenge. “We’ve thought a lot about the potential our tools will have on reducing carbon emissions, and we’ve done a really in-depth analysis looking at how our system can increase production yields of solar panels and other energy technologies, reducing materials and energy wasted in conventional optimization,” deQuilettes says. “If we look across all these sectors, we can expect to offset about 1,000 million metric tons of CO₂ [carbon dioxide] per year in the not-too-distant future.”

The team has written scale into its business plan. “We want to be the key enabler for bringing these new energy technologies to market,” says Motes. “We envision being deployed on every manufacturing line making these types of materials. It’s our goal to walk around and know that if we see a solar panel deployed, there’s a pretty high likelihood that it will be one we measured at some point.”

Perovskites, a broad class of compounds with a particular kind of crystal structure, have long been seen as a promising alternative or supplement to today’s silicon or cadmium telluride solar panels. They could be far more lightweight and inexpensive, and could be coated onto virtually any substrate, including paper or flexible plastic that could be rolled up for easy transport.

In their efficiency at converting sunlight to electricity, perovskites are becoming comparable to silicon, whose manufacture still requires long, complex, and energy-intensive processes. One big remaining drawback is longevity: They tend to break down in a matter of months to years, while silicon solar panels can last more than two decades. And their efficiency over large module areas still lags behind silicon. Now, a team of researchers at MIT and several other institutions has revealed ways to optimize efficiency and better control degradation, by engineering the nanoscale structure of perovskite devices.

The study reveals new insights on how to make high-efficiency perovskite solar cells, and also provides new directions for engineers working to bring these solar cells to the commercial marketplace. The work is described today in the journal Nature Energy, in a paper by Dane deQuilettes, a recent MIT postdoc who is now co-founder and chief science officer of the MIT spinout Optigon, along with MIT professors Vladimir Bulovic and Moungi Bawendi, and 10 others at MIT and in Washington state, the U.K., and Korea.

“Ten years ago, if you had asked us what would be the ultimate solution to the rapid development of solar technologies, the answer would have been something that works as well as silicon but whose manufacturing is much simpler,” Bulovic says. “And before we knew it, the field of perovskite photovoltaics appeared. They were as efficient as silicon, and they were as easy to paint on as it is to paint on a piece of paper. The result was tremendous excitement in the field.”

Nonetheless, “there are some significant technical challenges of handling and managing this material in ways we’ve never done before,” he says. But the promise is so great that many hundreds of researchers around the world have been working on this technology. The new study looks at a very small but key detail: how to “passivate” the material’s surface, changing its properties in such a way that the perovskite no longer degrades so rapidly or loses efficiency.

“The key is identifying the chemistry of the interfaces, the place where the perovskite meets other materials,” Bulovic says, referring to the places where different materials are stacked next to perovskite in order to facilitate the flow of current through the device.

Engineers have developed methods for passivation, for example by using a solution that creates a thin passivating coating. But they’ve lacked a detailed understanding of how this process works — which is essential to make further progress in finding better coatings. The new study “addressed the ability to passivate those interfaces and elucidate the physics and science behind why this passivation works as well as it does,” Bulovic says.

The team used some of the most powerful instruments available at laboratories around the world to observe the interfaces between the perovskite layer and other materials, and how they develop, in unprecedented detail. This close examination of the passivation coating process and its effects resulted in “the clearest roadmap as of yet of what we can do to fine-tune the energy alignment at the interfaces of perovskites and neighboring materials,” and thus improve their overall performance, Bulovic says.

While the bulk of a perovskite material is in the form of a perfectly ordered crystalline lattice of atoms, this order breaks down at the surface. There may be extra atoms sticking out or vacancies where atoms are missing, and these defects cause losses in the material’s efficiency. That’s where the need for passivation comes in.

“This paper is essentially revealing a guidebook for how to tune surfaces, where a lot of these defects are, to make sure that energy is not lost at surfaces,” deQuilettes says. “It’s a really big discovery for the field,” he says. “This is the first paper that demonstrates how to systematically control and engineer surface fields in perovskites.”

The common passivation method is to bathe the surface in a solution of a salt called hexylammonium bromide, a technique developed at MIT several years ago by Jason Jungwan Yoo PhD ’20, who is a co-author of this paper, that led to multiple new world-record efficiencies. By doing that “you form a very thin layer on top of your defective surface, and that thin layer actually passivates a lot of the defects really well,” deQuilettes says. “And then the bromine, which is part of the salt, actually penetrates into the three-dimensional layer in a controllable way.” That penetration helps to prevent electrons from losing energy to defects at the surface.

These two effects, produced by a single processing step, produces the two beneficial changes simultaneously. “It’s really beautiful because usually you need to do that in two steps,” deQuilettes says.

The passivation reduces the energy loss of electrons at the surface after they have been knocked loose by sunlight. These losses reduce the overall efficiency of the conversion of sunlight to electricity, so reducing the losses boosts the net efficiency of the cells.

That could rapidly lead to improvements in the materials’ efficiency in converting sunlight to electricity, he says. The recent efficiency records for a single perovskite layer, several of them set at MIT, have ranged from about 24 to 26 percent, while the maximum theoretical efficiency that could be reached is about 30 percent, according to deQuilettes.

An increase of a few percent may not sound like much, but in the solar photovoltaic industry such improvements are highly sought after. “In the silicon photovoltaic industry, if you’re gaining half of a percent in efficiency, that’s worth hundreds of millions of dollars on the global market,” he says. A recent shift in silicon cell design, essentially adding a thin passivating layer and changing the doping profile, provides an efficiency gain of about half of a percent. As a result, “the whole industry is shifting and rapidly trying to push to get there.” The overall efficiency of silicon solar cells has only seen very small incremental improvements for the last 30 years, he says.

The record efficiencies for perovskites have mostly been set in controlled laboratory settings with small postage-stamp-size samples of the material. “Translating a record efficiency to commercial scale takes a long time,” deQuilettes says. “Another big hope is that with this understanding, people will be able to better engineer large areas to have these passivating effects.”

There are hundreds of different kinds of passivating salts and many different kinds of perovskites, so the basic understanding of the passivation process provided by this new work could help guide researchers to find even better combinations of materials, the researchers suggest. “There are so many different ways you could engineer the materials,” he says.

“I think we are on the doorstep of the first practical demonstrations of perovskites in the commercial applications,” Bulovic says. “And those first applications will be a far cry from what we’ll be able to do a few years from now.” He adds that perovskites “should not be seen as a displacement of silicon photovoltaics. It should be seen as an augmentation — yet another way to bring about more rapid deployment of solar electricity.”

“A lot of progress has been made in the last two years on finding surface treatments that improve perovskite solar cells,” says Michael McGehee, a professor of chemical engineering at the University of Colorado who was not associated with this research. “A lot of the research has been empirical with the mechanisms behind the improvements not being fully understood. This detailed study shows that treatments can not only passivate defects, but can also create a surface field that repels carriers that should be collected at the other side of the device. This understanding might help further improve the interfaces.”

The team included researchers at the Korea Research Institute of Chemical Technology, Cambridge University, the University of Washington in Seattle, and Sungkyunkwan University in Korea. The work was supported by the Tata Trust, the MIT Institute for Soldier Nanotechnologies, the U.S. Department of Energy, and the U.S. National Science Foundation.

When Yifeng Chen was a teenager in Shantou, China, in the early 2000s, he saw a TV program that amazed him. The show highlighted rooftop solar panels in Germany, explaining that the panels generated electricity to power the buildings and even earned the owners money by letting them sell extra energy back to the electricity company.

Yifeng Chen

Employer

Trina Solar

Title

Assistant vice president of technology

Member Grade

Member

Alma Maters

Sun Yat-sen University, in Guangzhou, China, and Leibniz University Hannover, in Germany

An incredulous Chen marveled at not only the technology but also the economics. A power authority would pay its customers?

It sounded like magic: useful and valuable electricity extracted from simple sunlight. The wonder of it all has fueled his dreams ever since.

In 2013 Chen earned a Ph.D. in photovoltaic sciences and technologies, and today he’s assistant vice president of technology at China’s Trina Solar, a Changzhou-based company that is one of the largest PV manufacturers in the world. He leads the company’s R&D group, whose efforts have set more than two dozen world records for solar power efficiency and output.

For Chen’s contributions to the science and technology of photovoltaic energy conversion, the IEEE member received the 2023 IEEE Stuart R. Wenham Young Professional Award from the IEEE Electron Devices Society.

“I was quite surprised and so grateful” to receive the Wenham Award, Chen says. “It’s a very high-level recognition, and there are so many deserving experts from around the world.”

Trina Solar’s push for more efficient hardware

Today’s commercial solar panels typically achieve about 20 percent efficiency: They can turn one-fifth of captured sunlight into electricity. Chen’s group is trying to make the panels more efficient.

The group is focusing on optimizing solar cell designs, including the passivated emitter and rear cell (PERC), which is the industry standard for commodity solar panels.

Invented in 1983, PERCs are used today in nearly 90 percent of solar panels on the market. They incorporate coatings on the front and back to capture sunlight more effectively and to avoid losing energy, both at the surfaces and as the sunlight travels through the cell. The coatings, known as passivation layers, are made from materials such as silicon nitride, silicon dioxide, and aluminum oxide. The layers keep negatively charged free electrons and positively charged electron holes apart, preventing them from combining at the surface of the solar cell and wasting energy.

Chen and his team have developed several ways to boost the performance of PERC panels, hitting a record of 24.5 percent efficiency in 2022. One of the technologies is a multilayer antireflective coating that helps solar panels trap more light. They also created extremely fine metallization fingers—narrow lines on solar cells’ surfaces—to collect and transport the electric current and help capture more sunlight. And they developed an advanced method for laying the strips of conductive metal that run across the solar cell, known as bus bars.

Experts predict the maximum efficiency of PERC technology will be reached soon, topping out at about 25 percent.

IEEE Member Yifeng Chen displays an i-TOPCon solar module, which has a production efficiency of more than 23 percent and a power output of up to 720 watts.Trina Solar

“So the question is: How do we get solar cells even more efficient?” Chen says.

During the past few years he and his group have been working on tunnel oxide passivated contact (TOPCon) technology. A TOPCon cell uses a thin layer of “tunneling oxide” insulating material—typically silicon dioxide—which is applied to the solar cell’s surface. Similar to the passivation layers on PERC cells, the tunnel oxide stops free electrons and electron holes from combining and wasting energy.

In 2022 Trina created a TOPCon-type panel with a record 25.5 percent efficiency, and two months ago the company announced it had achieved a record 740.6 watts for a mass-produced TOPCon solar module. The latter was the 26th record Trina set for solar power–related efficiencies and outputs.

To achieve that record-breaking performance for their TOPCon panels, Chen and his team optimized the company’s manufacturing processes including laser-induced firing, in which a laser heats part of the solar cell and creates bonds between the metal contacts and the silicon wafer. The resulting connections are stronger and better aligned, enhancing efficiency.

“We’re trying to keep improving things to trap just a little bit more sunlight,” Chen says. “Gaining 1 or 2 percent more efficiency is huge. These may sound like very tiny increases, but at scale these small improvements create a lot of value in terms of economics, sustainability, and value to society.”

As the efficiency of solar cells rises and prices drop, Chen says, he expects solar power to continue to grow around the world. China currently leads the world in installed solar power capacity, accounting for about 40 percent of global capacity. The United States is a distant second, with 12 percent, according to a 2023 Rystad Energy report. The report predicts that China’s 500 gigawatts of solar capacity in 2023 is likely to exceed 1 terawatt by 2026.

“I’m inspired by using science to create something useful for human beings, and then driven by the pursuit for excellence,” Chen says. “We can always learn something new to make that change, improve that piece of technology, and get just that little bit better.”

Trained by solar-power pioneers

Chen attended Sun Yat-sen University in Guangzhou, China, earning a bachelor’s degree in optics sciences and technologies in 2008. He stayed on to pursue a Ph.D. in photovoltaics sciences and technologies. His research was on high-efficiency solar cells made from wafer-based crystalline silicon. His adviser was Hui Shen, a leading PV professor and founder of the university’s Institute for Solar Energy Systems. Chen calls him “the first of three very important figures in my scientific career.”

In 2011 Chen spent a year as a Ph.D. student at Leibniz University Hannover, in Germany. There he studied under Pietro P. Altermatt, the second influential figure in his career.

Altermatt—a prominent silicon solar-cell expert who would later become principal scientist at Trina—advised Chen on his computational techniques for modeling and analyzing the behavior of 2D and 3D solar cells. The models play a key role in designing solar cells to optimize their output.

“Gaining 1 or 2 percent more efficiency is huge. These may sound like very tiny increases, but at scale, these small improvements create a lot of value in terms of economics, sustainability, and value to society.”

“Dr. Altermatt changed how I look at things,” Chen says. “In Germany, they really focus on device physics.”

After completing his Ph.D., Chen became a technical assistant at Trina, where he met the third highly influential person in his career: Pierre Verlinden, a pioneering photovoltaic researcher who was the company’s chief scientist.

At Trina, Chen quickly ascended through R&D roles. He has been the company’s assistant vice president of technology since 2023.

IEEE’s “treasure” trove of research

Chen joined IEEE as a student because he wanted to attend the IEEE Photovoltaic Specialists Conference, the longest-running event dedicated to photovoltaics, solar cells, and solar power.

The membership was particularly beneficial during his Ph.D. studies, he says, because he used the IEEE Xplore Digital Library to access archival papers.

“My work has certainly been inspired by papers I found via IEEE,” Chen says. “Plus, you end up clicking around and reading other work that isn’t related to your field but is so interesting.

“The publication repository is a treasure. It’s eye-opening to see what’s going on inside and outside of your industry, with new discoveries happening all the time.”

The scorching surface of Venus, where temperatures can climb to 480 degrees Celsius (hot enough to melt lead), is an inhospitable place for humans and machines alike. One reason scientists have not yet been able to send a rover to the planet’s surface is because silicon-based electronics can’t operate in such extreme temperatures for an extended period of time.

For high-temperature applications like Venus exploration, researchers have recently turned to gallium nitride, a unique material that can withstand temperatures of 500 degrees or more.

The material is already used in some terrestrial electronics, like phone chargers and cell phone towers, but scientists don’t have a good grasp of how gallium nitride devices would behave at temperatures beyond 300 degrees, which is the operational limit of conventional silicon electronics.

In a new paper published in Applied Physics Letters, which is part of a multiyear research effort, a team of scientists from MIT and elsewhere sought to answer key questions about the material’s properties and performance at extremely high temperatures.  

They studied the impact of temperature on the ohmic contacts in a gallium nitride device. Ohmic contacts are key components that connect a semiconductor device with the outside world.

The researchers found that extreme temperatures didn’t cause significant degradation to the gallium nitride material or contacts. They were surprised to see that the contacts remained structurally intact even when held at 500 degrees Celsius for 48 hours.

Understanding how contacts perform at extreme temperatures is an important step toward the group’s next goal of developing high-performance transistors that could operate on the surface of Venus. Such transistors could also be used on Earth in electronics for applications like extracting geothermal energy or monitoring the inside of jet engines.

“Transistors are the heart of most modern electronics, but we didn’t want to jump straight to making a gallium nitride transistor because so much could go wrong. We first wanted to make sure the material and contacts could survive, and figure out how much they change as you increase the temperature. We’ll design our transistor from these basic material building blocks,” says John Niroula, an electrical engineering and computer science (EECS) graduate student and lead author of the paper.

His co-authors include Qingyun Xie PhD ’24; Mengyang Yuan PhD ’22; EECS graduate students Patrick K. Darmawi-Iskandar and Pradyot Yadav; Gillian K. Micale, a graduate student in the Department of Materials Science and Engineering; senior author Tomás Palacios, the Clarence J. LeBel Professor of EECS, director of the Microsystems Technology Laboratories, and a member of the Research Laboratory of Electronics; as well as collaborators Nitul S. Rajput of the Technology Innovation Institute of the United Arab Emirates; Siddharth Rajan of Ohio State University; Yuji Zhao of Rice University; and Nadim Chowdhury of Bangladesh University of Engineering and Technology.

Turning up the heat

While gallium nitride has recently attracted much attention, the material is still decades behind silicon when it comes to scientists’ understanding of how its properties change under different conditions. One such property is resistance, the flow of electrical current through a material.

A device’s overall resistance is inversely proportional to its size. But devices like semiconductors have contacts that connect them to other electronics. Contact resistance, which is caused by these electrical connections, remains fixed no matter the size of the device. Too much contact resistance can lead to higher power dissipation and slower operating frequencies for electronic circuits.

“Especially when you go to smaller dimensions, a device’s performance often ends up being limited by contact resistance. People have a relatively good understanding of contact resistance at room temperature, but no one has really studied what happens when you go all the way up to 500 degrees,” Niroula says.

For their study, the researchers used facilities at MIT.nano to build gallium nitride devices known as transfer length method structures, which are composed of a series of resistors. These devices enable them to measure the resistance of both the material and the contacts.

They added ohmic contacts to these devices using the two most common methods. The first involves depositing metal onto gallium nitride and heating it to 825 degrees Celsius for about 30 seconds, a process called annealing.

The second method involves removing chunks of gallium nitride and using a high-temperature technology to regrow highly doped gallium nitride in its place, a process led by Rajan and his team at Ohio State. The highly doped material contains extra electrons that can contribute to current conduction.

“The regrowth method typically leads to lower contact resistance at room temperature, but we wanted to see if these methods still work well at high temperatures,” Niroula says.

A comprehensive approach

They tested devices in two ways. Their collaborators at Rice University, led by Zhao, conducted short-term tests by placing devices on a hot chuck that reached 500 degrees Celsius and taking immediate resistance measurements.

At MIT, they conducted longer-term experiments by placing devices into a specialized furnace the group previously developed. They left devices inside for up to 72 hours to measure how resistance changes as a function of temperature and time.

Microscopy experts at MIT.nano (Aubrey N. Penn) and the Technology Innovation Institute (Nitul S. Rajput) used state-of-the-art transmission electron microscopes to see how such high temperatures affect gallium nitride and the ohmic contacts at the atomic level.

“We went in thinking the contacts or the gallium nitride material itself would degrade significantly, but we found the opposite. Contacts made with both methods seemed to be remarkably stable,” says Niroula.

While it is difficult to measure resistance at such high temperatures, their results indicate that contact resistance seems to remain constant even at temperatures of 500 degrees, for around 48 hours. And just like at room temperature, the regrowth process led to better performance.

The material did start to degrade after being in the furnace for 48 hours, but the researchers are already working to boost long-term performance. One strategy involves adding protective insulators to keep the material from being directly exposed to the high-temperature environment.

Moving forward, the researchers plan to use what they learned in these experiments to develop high-temperature gallium nitride transistors.

“In our group, we focus on innovative, device-level research to advance the frontiers of microelectronics, while adopting a systematic approach across the hierarchy, from the material level to the circuit level. Here, we have gone all the way down to the material level to understand things in depth. In other words, we have translated device-level advancements to circuit-level impact for high-temperature electronics, through design, modeling and complex fabrication. We are also immensely fortunate to have forged close partnerships with our longtime collaborators in this journey,” Xie says.

This work was funded, in part, by the U.S. Air Force Office of Scientific Research, Lockheed Martin Corporation, the Semiconductor Research Corporation through the U.S. Defense Advanced Research Projects Agency, the U.S. Department of Energy, Intel Corporation, and the Bangladesh University of Engineering and Technology.

Fabrication and microscopy were conducted at MIT.nano, the Semiconductor Epitaxy and Analysis Laboratory at Ohio State University, the Center for Advanced Materials Characterization at the University of Oregon, and the Technology Innovation Institute of the United Arab Emirates.

Consider the dizzying ascent of solar energy in the United States: In the past decade, solar capacity increased nearly 900 percent, with electricity production eight times greater in 2023 than in 2014. The jump from 2022 to 2023 alone was 51 percent, with a record 32 gigawatts (GW) of solar installations coming online. In the past four years, more solar has been added to the grid than any other form of generation. Installed solar now tops 179 GW, enough to power nearly 33 million homes. The U.S. Department of Energy (DOE) is so bullish on the sun that its decarbonization plans envision solar satisfying 45 percent of the nation’s electricity demands by 2050.

But the continued rapid expansion of solar requires advances in technology, notably to improve the efficiency and durability of solar photovoltaic (PV) materials and manufacturing. That’s where Optigon, a three-year-old MIT spinout company, comes in.

“Our goal is to build tools for research and industry that can accelerate the energy transition,” says Dane deQuilettes, the company’s co-founder and chief science officer. “The technology we have developed for solar will enable measurements and analysis of materials as they are being made both in lab and on the manufacturing line, dramatically speeding up the optimization of PV.”

With roots in MIT’s vibrant solar research community, Optigon is poised for a 2024 rollout of technology it believes will drastically pick up the pace of solar power and other clean energy projects.

Beyond silicon

Silicon, the material mainstay of most PV, is limited by the laws of physics in the efficiencies it can achieve converting photons from the sun into electrical energy. Silicon-based solar cells can theoretically reach power conversion levels of just 30 percent, and real-world efficiency levels hover in the low 20s. But beyond the physical limitations of silicon, there is another issue at play for many researchers and the solar industry in the United States and elsewhere: China dominates the silicon PV market, from supply chains to manufacturing.

Scientists are eagerly pursuing alternative materials, either for enhancing silicon’s solar conversion capacity or for replacing silicon altogether.

In the past decade, a family of crystal-structured semiconductors known as perovskites has risen to the fore as a next-generation PV material candidate. Perovskite devices lend themselves to a novel manufacturing process using printing technology that could circumvent the supply chain juggernaut China has built for silicon. Perovskite solar cells can be stacked on each other or layered atop silicon PV, to achieve higher conversion efficiencies. Because perovskite technology is flexible and lightweight, modules can be used on roofs and other structures that cannot support heavier silicon PV, lowering costs and enabling a wider range of building-integrated solar devices.

But these new materials require testing, both during R&D and then on assembly lines, where missing or defective optical, electrical, or dimensional properties in the nano-sized crystal structures can negatively impact the end product.

“The actual measurement and data analysis processes have been really, really slow, because you have to use a bunch of separate tools that are all very manual,” says Optigon co-founder and chief executive officer Anthony Troupe ’21. “We wanted to come up with tools for automating detection of a material’s properties, for determining whether it could make a good or bad solar cell, and then for optimizing it.”

“Our approach packed several non-contact, optical measurements using different types of light sources and detectors into a single system, which together provide a holistic, cross-sectional view of the material,” says Brandon Motes ’21, ME ’22, co-founder and chief technical officer.

“This breakthrough in achieving millisecond timescales for data collection and analysis means we can take research-quality tools and actually put them on a full production system, getting extremely detailed information about products being built at massive, gigawatt scale in real-time,” says Troupe.

This streamlined system takes measurements “in the snap of the fingers, unlike the traditional tools,” says Joseph Berry, director of the US Manufacturing of Advanced Perovskites Consortium and a senior research scientist at the National Renewable Energy Laboratory. “Optigon’s techniques are high precision and allow high throughput, which means they can be used in a lot of contexts where you want rapid feedback and the ability to develop materials very, very quickly.”

According to Berry, Optigon’s technology may give the solar industry not just better materials, but the ability to pump out high-quality PV products at a brisker clip than is currently possible. “If Optigon is successful in deploying their technology, then we can more rapidly develop the materials that we need, manufacturing with the requisite precision again and again,” he says. “This could lead to the next generation of PV modules at a much, much lower cost.”

Measuring makes the difference

With Small Business Innovation Research funding from DOE to commercialize its products and a grant from the Massachusetts Clean Energy Center, Optigon has settled into a space at the climate technology incubator Greentown Labs in Somerville, Massachusetts. Here, the team is preparing for this spring’s launch of its first commercial product, whose genesis lies in MIT’s GridEdge Solar Research Program.

Led by Vladimir Bulović, a professor of electrical engineering and the director of MIT.nano, the GridEdge program was established with funding from the Tata Trusts to develop lightweight, flexible, and inexpensive solar cells for distribution to rural communities around the globe. When deQuilettes joined the group in 2017 as a postdoc, he was tasked with directing the program and building the infrastructure to study and make perovskite solar modules.

“We were trying to understand once we made the material whether or not it was good,” he recalls. “There were no good commercial metrology [the science of measurements] tools for materials beyond silicon, so we started to build our own.” Recognizing the group’s need for greater expertise on the problem, especially in the areas of electrical, software, and mechanical engineering, deQuilettes put a call out for undergraduate researchers to help build metrology tools for new solar materials.

“Forty people inquired, but when I met Brandon and Anthony, something clicked; it was clear we had a complementary skill set,” says deQuilettes. “We started working together, with Anthony coming up with beautiful designs to integrate multiple measurements, and Brandon creating boards to control all of the hardware, including different types of lasers. We started filing multiple patents and that was when we saw it all coming together.”

“We knew from the start that metrology could vastly improve not just materials, but production yields,” says Troupe. Adds deQuilettes, “Our goal was getting to the highest performance orders of magnitude faster than it would ordinarily take, so we developed tools that would not just be useful for research labs but for manufacturing lines to give live feedback on quality.”

The device Optigon designed for industry is the size of a football, “with sensor packages crammed into a tiny form factor, taking measurements as material flows directly underneath,” says Motes. “We have also thought carefully about ways to make interaction with this tool as seamless and, dare I say, as enjoyable as possible, streaming data to both a dashboard an operator can watch and to a custom database.”

Photovoltaics is just the start

The company may have already found its market niche. “A research group paid us to use our in-house prototype because they have such a burning need to get these sorts of measurements,” says Troupe, and according to Motes, “Potential customers ask us if they can buy the system now.” deQuilettes says, “Our hope is that we become the de facto company for doing any sort of characterization metrology in the United States and beyond.”

Challenges lie ahead for Optigon: product launches, full-scale manufacturing, technical assistance, and sales. Greentown Labs offers support, as does MIT’s own rich community of solar researchers and entrepreneurs. But the founders are already thinking about next phases.

“We are not limiting ourselves to the photovoltaics area,” says deQuilettes. “We’re planning on working in other clean energy materials such as batteries and fuel cells.”

That’s because the team wants to make the maximum impact on the climate challenge. “We’ve thought a lot about the potential our tools will have on reducing carbon emissions, and we’ve done a really in-depth analysis looking at how our system can increase production yields of solar panels and other energy technologies, reducing materials and energy wasted in conventional optimization,” deQuilettes says. “If we look across all these sectors, we can expect to offset about 1,000 million metric tons of CO₂ [carbon dioxide] per year in the not-too-distant future.”

The team has written scale into its business plan. “We want to be the key enabler for bringing these new energy technologies to market,” says Motes. “We envision being deployed on every manufacturing line making these types of materials. It’s our goal to walk around and know that if we see a solar panel deployed, there’s a pretty high likelihood that it will be one we measured at some point.”

Perovskites, a broad class of compounds with a particular kind of crystal structure, have long been seen as a promising alternative or supplement to today’s silicon or cadmium telluride solar panels. They could be far more lightweight and inexpensive, and could be coated onto virtually any substrate, including paper or flexible plastic that could be rolled up for easy transport.

In their efficiency at converting sunlight to electricity, perovskites are becoming comparable to silicon, whose manufacture still requires long, complex, and energy-intensive processes. One big remaining drawback is longevity: They tend to break down in a matter of months to years, while silicon solar panels can last more than two decades. And their efficiency over large module areas still lags behind silicon. Now, a team of researchers at MIT and several other institutions has revealed ways to optimize efficiency and better control degradation, by engineering the nanoscale structure of perovskite devices.

The study reveals new insights on how to make high-efficiency perovskite solar cells, and also provides new directions for engineers working to bring these solar cells to the commercial marketplace. The work is described today in the journal Nature Energy, in a paper by Dane deQuilettes, a recent MIT postdoc who is now co-founder and chief science officer of the MIT spinout Optigon, along with MIT professors Vladimir Bulovic and Moungi Bawendi, and 10 others at MIT and in Washington state, the U.K., and Korea.

“Ten years ago, if you had asked us what would be the ultimate solution to the rapid development of solar technologies, the answer would have been something that works as well as silicon but whose manufacturing is much simpler,” Bulovic says. “And before we knew it, the field of perovskite photovoltaics appeared. They were as efficient as silicon, and they were as easy to paint on as it is to paint on a piece of paper. The result was tremendous excitement in the field.”

Nonetheless, “there are some significant technical challenges of handling and managing this material in ways we’ve never done before,” he says. But the promise is so great that many hundreds of researchers around the world have been working on this technology. The new study looks at a very small but key detail: how to “passivate” the material’s surface, changing its properties in such a way that the perovskite no longer degrades so rapidly or loses efficiency.

“The key is identifying the chemistry of the interfaces, the place where the perovskite meets other materials,” Bulovic says, referring to the places where different materials are stacked next to perovskite in order to facilitate the flow of current through the device.

Engineers have developed methods for passivation, for example by using a solution that creates a thin passivating coating. But they’ve lacked a detailed understanding of how this process works — which is essential to make further progress in finding better coatings. The new study “addressed the ability to passivate those interfaces and elucidate the physics and science behind why this passivation works as well as it does,” Bulovic says.

The team used some of the most powerful instruments available at laboratories around the world to observe the interfaces between the perovskite layer and other materials, and how they develop, in unprecedented detail. This close examination of the passivation coating process and its effects resulted in “the clearest roadmap as of yet of what we can do to fine-tune the energy alignment at the interfaces of perovskites and neighboring materials,” and thus improve their overall performance, Bulovic says.

While the bulk of a perovskite material is in the form of a perfectly ordered crystalline lattice of atoms, this order breaks down at the surface. There may be extra atoms sticking out or vacancies where atoms are missing, and these defects cause losses in the material’s efficiency. That’s where the need for passivation comes in.

“This paper is essentially revealing a guidebook for how to tune surfaces, where a lot of these defects are, to make sure that energy is not lost at surfaces,” deQuilettes says. “It’s a really big discovery for the field,” he says. “This is the first paper that demonstrates how to systematically control and engineer surface fields in perovskites.”

The common passivation method is to bathe the surface in a solution of a salt called hexylammonium bromide, a technique developed at MIT several years ago by Jason Jungwan Yoo PhD ’20, who is a co-author of this paper, that led to multiple new world-record efficiencies. By doing that “you form a very thin layer on top of your defective surface, and that thin layer actually passivates a lot of the defects really well,” deQuilettes says. “And then the bromine, which is part of the salt, actually penetrates into the three-dimensional layer in a controllable way.” That penetration helps to prevent electrons from losing energy to defects at the surface.

These two effects, produced by a single processing step, produces the two beneficial changes simultaneously. “It’s really beautiful because usually you need to do that in two steps,” deQuilettes says.

The passivation reduces the energy loss of electrons at the surface after they have been knocked loose by sunlight. These losses reduce the overall efficiency of the conversion of sunlight to electricity, so reducing the losses boosts the net efficiency of the cells.

That could rapidly lead to improvements in the materials’ efficiency in converting sunlight to electricity, he says. The recent efficiency records for a single perovskite layer, several of them set at MIT, have ranged from about 24 to 26 percent, while the maximum theoretical efficiency that could be reached is about 30 percent, according to deQuilettes.

An increase of a few percent may not sound like much, but in the solar photovoltaic industry such improvements are highly sought after. “In the silicon photovoltaic industry, if you’re gaining half of a percent in efficiency, that’s worth hundreds of millions of dollars on the global market,” he says. A recent shift in silicon cell design, essentially adding a thin passivating layer and changing the doping profile, provides an efficiency gain of about half of a percent. As a result, “the whole industry is shifting and rapidly trying to push to get there.” The overall efficiency of silicon solar cells has only seen very small incremental improvements for the last 30 years, he says.

The record efficiencies for perovskites have mostly been set in controlled laboratory settings with small postage-stamp-size samples of the material. “Translating a record efficiency to commercial scale takes a long time,” deQuilettes says. “Another big hope is that with this understanding, people will be able to better engineer large areas to have these passivating effects.”

There are hundreds of different kinds of passivating salts and many different kinds of perovskites, so the basic understanding of the passivation process provided by this new work could help guide researchers to find even better combinations of materials, the researchers suggest. “There are so many different ways you could engineer the materials,” he says.

“I think we are on the doorstep of the first practical demonstrations of perovskites in the commercial applications,” Bulovic says. “And those first applications will be a far cry from what we’ll be able to do a few years from now.” He adds that perovskites “should not be seen as a displacement of silicon photovoltaics. It should be seen as an augmentation — yet another way to bring about more rapid deployment of solar electricity.”

“A lot of progress has been made in the last two years on finding surface treatments that improve perovskite solar cells,” says Michael McGehee, a professor of chemical engineering at the University of Colorado who was not associated with this research. “A lot of the research has been empirical with the mechanisms behind the improvements not being fully understood. This detailed study shows that treatments can not only passivate defects, but can also create a surface field that repels carriers that should be collected at the other side of the device. This understanding might help further improve the interfaces.”

The team included researchers at the Korea Research Institute of Chemical Technology, Cambridge University, the University of Washington in Seattle, and Sungkyunkwan University in Korea. The work was supported by the Tata Trust, the MIT Institute for Soldier Nanotechnologies, the U.S. Department of Energy, and the U.S. National Science Foundation.

The scorching surface of Venus, where temperatures can climb to 480 degrees Celsius (hot enough to melt lead), is an inhospitable place for humans and machines alike. One reason scientists have not yet been able to send a rover to the planet’s surface is because silicon-based electronics can’t operate in such extreme temperatures for an extended period of time.

For high-temperature applications like Venus exploration, researchers have recently turned to gallium nitride, a unique material that can withstand temperatures of 500 degrees or more.

The material is already used in some terrestrial electronics, like phone chargers and cell phone towers, but scientists don’t have a good grasp of how gallium nitride devices would behave at temperatures beyond 300 degrees, which is the operational limit of conventional silicon electronics.

In a new paper published in Applied Physics Letters, which is part of a multiyear research effort, a team of scientists from MIT and elsewhere sought to answer key questions about the material’s properties and performance at extremely high temperatures.  

They studied the impact of temperature on the ohmic contacts in a gallium nitride device. Ohmic contacts are key components that connect a semiconductor device with the outside world.

The researchers found that extreme temperatures didn’t cause significant degradation to the gallium nitride material or contacts. They were surprised to see that the contacts remained structurally intact even when held at 500 degrees Celsius for 48 hours.

Understanding how contacts perform at extreme temperatures is an important step toward the group’s next goal of developing high-performance transistors that could operate on the surface of Venus. Such transistors could also be used on Earth in electronics for applications like extracting geothermal energy or monitoring the inside of jet engines.

“Transistors are the heart of most modern electronics, but we didn’t want to jump straight to making a gallium nitride transistor because so much could go wrong. We first wanted to make sure the material and contacts could survive, and figure out how much they change as you increase the temperature. We’ll design our transistor from these basic material building blocks,” says John Niroula, an electrical engineering and computer science (EECS) graduate student and lead author of the paper.

His co-authors include Qingyun Xie PhD ’24; Mengyang Yuan PhD ’22; EECS graduate students Patrick K. Darmawi-Iskandar and Pradyot Yadav; Gillian K. Micale, a graduate student in the Department of Materials Science and Engineering; senior author Tomás Palacios, the Clarence J. LeBel Professor of EECS, director of the Microsystems Technology Laboratories, and a member of the Research Laboratory of Electronics; as well as collaborators Nitul S. Rajput of the Technology Innovation Institute of the United Arab Emirates; Siddharth Rajan of Ohio State University; Yuji Zhao of Rice University; and Nadim Chowdhury of Bangladesh University of Engineering and Technology.

Turning up the heat

While gallium nitride has recently attracted much attention, the material is still decades behind silicon when it comes to scientists’ understanding of how its properties change under different conditions. One such property is resistance, the flow of electrical current through a material.

A device’s overall resistance is inversely proportional to its size. But devices like semiconductors have contacts that connect them to other electronics. Contact resistance, which is caused by these electrical connections, remains fixed no matter the size of the device. Too much contact resistance can lead to higher power dissipation and slower operating frequencies for electronic circuits.

“Especially when you go to smaller dimensions, a device’s performance often ends up being limited by contact resistance. People have a relatively good understanding of contact resistance at room temperature, but no one has really studied what happens when you go all the way up to 500 degrees,” Niroula says.

For their study, the researchers used facilities at MIT.nano to build gallium nitride devices known as transfer length method structures, which are composed of a series of resistors. These devices enable them to measure the resistance of both the material and the contacts.

They added ohmic contacts to these devices using the two most common methods. The first involves depositing metal onto gallium nitride and heating it to 825 degrees Celsius for about 30 seconds, a process called annealing.

The second method involves removing chunks of gallium nitride and using a high-temperature technology to regrow highly doped gallium nitride in its place, a process led by Rajan and his team at Ohio State. The highly doped material contains extra electrons that can contribute to current conduction.

“The regrowth method typically leads to lower contact resistance at room temperature, but we wanted to see if these methods still work well at high temperatures,” Niroula says.

A comprehensive approach

They tested devices in two ways. Their collaborators at Rice University, led by Zhao, conducted short-term tests by placing devices on a hot chuck that reached 500 degrees Celsius and taking immediate resistance measurements.

At MIT, they conducted longer-term experiments by placing devices into a specialized furnace the group previously developed. They left devices inside for up to 72 hours to measure how resistance changes as a function of temperature and time.

Microscopy experts at MIT.nano (Aubrey N. Penn) and the Technology Innovation Institute (Nitul S. Rajput) used state-of-the-art transmission electron microscopes to see how such high temperatures affect gallium nitride and the ohmic contacts at the atomic level.

“We went in thinking the contacts or the gallium nitride material itself would degrade significantly, but we found the opposite. Contacts made with both methods seemed to be remarkably stable,” says Niroula.

While it is difficult to measure resistance at such high temperatures, their results indicate that contact resistance seems to remain constant even at temperatures of 500 degrees, for around 48 hours. And just like at room temperature, the regrowth process led to better performance.

The material did start to degrade after being in the furnace for 48 hours, but the researchers are already working to boost long-term performance. One strategy involves adding protective insulators to keep the material from being directly exposed to the high-temperature environment.

Moving forward, the researchers plan to use what they learned in these experiments to develop high-temperature gallium nitride transistors.

“In our group, we focus on innovative, device-level research to advance the frontiers of microelectronics, while adopting a systematic approach across the hierarchy, from the material level to the circuit level. Here, we have gone all the way down to the material level to understand things in depth. In other words, we have translated device-level advancements to circuit-level impact for high-temperature electronics, through design, modeling and complex fabrication. We are also immensely fortunate to have forged close partnerships with our longtime collaborators in this journey,” Xie says.

This work was funded, in part, by the U.S. Air Force Office of Scientific Research, Lockheed Martin Corporation, the Semiconductor Research Corporation through the U.S. Defense Advanced Research Projects Agency, the U.S. Department of Energy, Intel Corporation, and the Bangladesh University of Engineering and Technology.

Fabrication and microscopy were conducted at MIT.nano, the Semiconductor Epitaxy and Analysis Laboratory at Ohio State University, the Center for Advanced Materials Characterization at the University of Oregon, and the Technology Innovation Institute of the United Arab Emirates.

Consider the dizzying ascent of solar energy in the United States: In the past decade, solar capacity increased nearly 900 percent, with electricity production eight times greater in 2023 than in 2014. The jump from 2022 to 2023 alone was 51 percent, with a record 32 gigawatts (GW) of solar installations coming online. In the past four years, more solar has been added to the grid than any other form of generation. Installed solar now tops 179 GW, enough to power nearly 33 million homes. The U.S. Department of Energy (DOE) is so bullish on the sun that its decarbonization plans envision solar satisfying 45 percent of the nation’s electricity demands by 2050.

But the continued rapid expansion of solar requires advances in technology, notably to improve the efficiency and durability of solar photovoltaic (PV) materials and manufacturing. That’s where Optigon, a three-year-old MIT spinout company, comes in.

“Our goal is to build tools for research and industry that can accelerate the energy transition,” says Dane deQuilettes, the company’s co-founder and chief science officer. “The technology we have developed for solar will enable measurements and analysis of materials as they are being made both in lab and on the manufacturing line, dramatically speeding up the optimization of PV.”

With roots in MIT’s vibrant solar research community, Optigon is poised for a 2024 rollout of technology it believes will drastically pick up the pace of solar power and other clean energy projects.

Beyond silicon

Silicon, the material mainstay of most PV, is limited by the laws of physics in the efficiencies it can achieve converting photons from the sun into electrical energy. Silicon-based solar cells can theoretically reach power conversion levels of just 30 percent, and real-world efficiency levels hover in the low 20s. But beyond the physical limitations of silicon, there is another issue at play for many researchers and the solar industry in the United States and elsewhere: China dominates the silicon PV market, from supply chains to manufacturing.

Scientists are eagerly pursuing alternative materials, either for enhancing silicon’s solar conversion capacity or for replacing silicon altogether.

In the past decade, a family of crystal-structured semiconductors known as perovskites has risen to the fore as a next-generation PV material candidate. Perovskite devices lend themselves to a novel manufacturing process using printing technology that could circumvent the supply chain juggernaut China has built for silicon. Perovskite solar cells can be stacked on each other or layered atop silicon PV, to achieve higher conversion efficiencies. Because perovskite technology is flexible and lightweight, modules can be used on roofs and other structures that cannot support heavier silicon PV, lowering costs and enabling a wider range of building-integrated solar devices.

But these new materials require testing, both during R&D and then on assembly lines, where missing or defective optical, electrical, or dimensional properties in the nano-sized crystal structures can negatively impact the end product.

“The actual measurement and data analysis processes have been really, really slow, because you have to use a bunch of separate tools that are all very manual,” says Optigon co-founder and chief executive officer Anthony Troupe ’21. “We wanted to come up with tools for automating detection of a material’s properties, for determining whether it could make a good or bad solar cell, and then for optimizing it.”

“Our approach packed several non-contact, optical measurements using different types of light sources and detectors into a single system, which together provide a holistic, cross-sectional view of the material,” says Brandon Motes ’21, ME ’22, co-founder and chief technical officer.

“This breakthrough in achieving millisecond timescales for data collection and analysis means we can take research-quality tools and actually put them on a full production system, getting extremely detailed information about products being built at massive, gigawatt scale in real-time,” says Troupe.

This streamlined system takes measurements “in the snap of the fingers, unlike the traditional tools,” says Joseph Berry, director of the US Manufacturing of Advanced Perovskites Consortium and a senior research scientist at the National Renewable Energy Laboratory. “Optigon’s techniques are high precision and allow high throughput, which means they can be used in a lot of contexts where you want rapid feedback and the ability to develop materials very, very quickly.”

According to Berry, Optigon’s technology may give the solar industry not just better materials, but the ability to pump out high-quality PV products at a brisker clip than is currently possible. “If Optigon is successful in deploying their technology, then we can more rapidly develop the materials that we need, manufacturing with the requisite precision again and again,” he says. “This could lead to the next generation of PV modules at a much, much lower cost.”

Measuring makes the difference

With Small Business Innovation Research funding from DOE to commercialize its products and a grant from the Massachusetts Clean Energy Center, Optigon has settled into a space at the climate technology incubator Greentown Labs in Somerville, Massachusetts. Here, the team is preparing for this spring’s launch of its first commercial product, whose genesis lies in MIT’s GridEdge Solar Research Program.

Led by Vladimir Bulović, a professor of electrical engineering and the director of MIT.nano, the GridEdge program was established with funding from the Tata Trusts to develop lightweight, flexible, and inexpensive solar cells for distribution to rural communities around the globe. When deQuilettes joined the group in 2017 as a postdoc, he was tasked with directing the program and building the infrastructure to study and make perovskite solar modules.

“We were trying to understand once we made the material whether or not it was good,” he recalls. “There were no good commercial metrology [the science of measurements] tools for materials beyond silicon, so we started to build our own.” Recognizing the group’s need for greater expertise on the problem, especially in the areas of electrical, software, and mechanical engineering, deQuilettes put a call out for undergraduate researchers to help build metrology tools for new solar materials.

“Forty people inquired, but when I met Brandon and Anthony, something clicked; it was clear we had a complementary skill set,” says deQuilettes. “We started working together, with Anthony coming up with beautiful designs to integrate multiple measurements, and Brandon creating boards to control all of the hardware, including different types of lasers. We started filing multiple patents and that was when we saw it all coming together.”

“We knew from the start that metrology could vastly improve not just materials, but production yields,” says Troupe. Adds deQuilettes, “Our goal was getting to the highest performance orders of magnitude faster than it would ordinarily take, so we developed tools that would not just be useful for research labs but for manufacturing lines to give live feedback on quality.”

The device Optigon designed for industry is the size of a football, “with sensor packages crammed into a tiny form factor, taking measurements as material flows directly underneath,” says Motes. “We have also thought carefully about ways to make interaction with this tool as seamless and, dare I say, as enjoyable as possible, streaming data to both a dashboard an operator can watch and to a custom database.”

Photovoltaics is just the start

The company may have already found its market niche. “A research group paid us to use our in-house prototype because they have such a burning need to get these sorts of measurements,” says Troupe, and according to Motes, “Potential customers ask us if they can buy the system now.” deQuilettes says, “Our hope is that we become the de facto company for doing any sort of characterization metrology in the United States and beyond.”

Challenges lie ahead for Optigon: product launches, full-scale manufacturing, technical assistance, and sales. Greentown Labs offers support, as does MIT’s own rich community of solar researchers and entrepreneurs. But the founders are already thinking about next phases.

“We are not limiting ourselves to the photovoltaics area,” says deQuilettes. “We’re planning on working in other clean energy materials such as batteries and fuel cells.”

That’s because the team wants to make the maximum impact on the climate challenge. “We’ve thought a lot about the potential our tools will have on reducing carbon emissions, and we’ve done a really in-depth analysis looking at how our system can increase production yields of solar panels and other energy technologies, reducing materials and energy wasted in conventional optimization,” deQuilettes says. “If we look across all these sectors, we can expect to offset about 1,000 million metric tons of CO₂ [carbon dioxide] per year in the not-too-distant future.”

The team has written scale into its business plan. “We want to be the key enabler for bringing these new energy technologies to market,” says Motes. “We envision being deployed on every manufacturing line making these types of materials. It’s our goal to walk around and know that if we see a solar panel deployed, there’s a pretty high likelihood that it will be one we measured at some point.”

Perovskites, a broad class of compounds with a particular kind of crystal structure, have long been seen as a promising alternative or supplement to today’s silicon or cadmium telluride solar panels. They could be far more lightweight and inexpensive, and could be coated onto virtually any substrate, including paper or flexible plastic that could be rolled up for easy transport.

In their efficiency at converting sunlight to electricity, perovskites are becoming comparable to silicon, whose manufacture still requires long, complex, and energy-intensive processes. One big remaining drawback is longevity: They tend to break down in a matter of months to years, while silicon solar panels can last more than two decades. And their efficiency over large module areas still lags behind silicon. Now, a team of researchers at MIT and several other institutions has revealed ways to optimize efficiency and better control degradation, by engineering the nanoscale structure of perovskite devices.

The study reveals new insights on how to make high-efficiency perovskite solar cells, and also provides new directions for engineers working to bring these solar cells to the commercial marketplace. The work is described today in the journal Nature Energy, in a paper by Dane deQuilettes, a recent MIT postdoc who is now co-founder and chief science officer of the MIT spinout Optigon, along with MIT professors Vladimir Bulovic and Moungi Bawendi, and 10 others at MIT and in Washington state, the U.K., and Korea.

“Ten years ago, if you had asked us what would be the ultimate solution to the rapid development of solar technologies, the answer would have been something that works as well as silicon but whose manufacturing is much simpler,” Bulovic says. “And before we knew it, the field of perovskite photovoltaics appeared. They were as efficient as silicon, and they were as easy to paint on as it is to paint on a piece of paper. The result was tremendous excitement in the field.”

Nonetheless, “there are some significant technical challenges of handling and managing this material in ways we’ve never done before,” he says. But the promise is so great that many hundreds of researchers around the world have been working on this technology. The new study looks at a very small but key detail: how to “passivate” the material’s surface, changing its properties in such a way that the perovskite no longer degrades so rapidly or loses efficiency.

“The key is identifying the chemistry of the interfaces, the place where the perovskite meets other materials,” Bulovic says, referring to the places where different materials are stacked next to perovskite in order to facilitate the flow of current through the device.

Engineers have developed methods for passivation, for example by using a solution that creates a thin passivating coating. But they’ve lacked a detailed understanding of how this process works — which is essential to make further progress in finding better coatings. The new study “addressed the ability to passivate those interfaces and elucidate the physics and science behind why this passivation works as well as it does,” Bulovic says.

The team used some of the most powerful instruments available at laboratories around the world to observe the interfaces between the perovskite layer and other materials, and how they develop, in unprecedented detail. This close examination of the passivation coating process and its effects resulted in “the clearest roadmap as of yet of what we can do to fine-tune the energy alignment at the interfaces of perovskites and neighboring materials,” and thus improve their overall performance, Bulovic says.

While the bulk of a perovskite material is in the form of a perfectly ordered crystalline lattice of atoms, this order breaks down at the surface. There may be extra atoms sticking out or vacancies where atoms are missing, and these defects cause losses in the material’s efficiency. That’s where the need for passivation comes in.

“This paper is essentially revealing a guidebook for how to tune surfaces, where a lot of these defects are, to make sure that energy is not lost at surfaces,” deQuilettes says. “It’s a really big discovery for the field,” he says. “This is the first paper that demonstrates how to systematically control and engineer surface fields in perovskites.”

The common passivation method is to bathe the surface in a solution of a salt called hexylammonium bromide, a technique developed at MIT several years ago by Jason Jungwan Yoo PhD ’20, who is a co-author of this paper, that led to multiple new world-record efficiencies. By doing that “you form a very thin layer on top of your defective surface, and that thin layer actually passivates a lot of the defects really well,” deQuilettes says. “And then the bromine, which is part of the salt, actually penetrates into the three-dimensional layer in a controllable way.” That penetration helps to prevent electrons from losing energy to defects at the surface.

These two effects, produced by a single processing step, produces the two beneficial changes simultaneously. “It’s really beautiful because usually you need to do that in two steps,” deQuilettes says.

The passivation reduces the energy loss of electrons at the surface after they have been knocked loose by sunlight. These losses reduce the overall efficiency of the conversion of sunlight to electricity, so reducing the losses boosts the net efficiency of the cells.

That could rapidly lead to improvements in the materials’ efficiency in converting sunlight to electricity, he says. The recent efficiency records for a single perovskite layer, several of them set at MIT, have ranged from about 24 to 26 percent, while the maximum theoretical efficiency that could be reached is about 30 percent, according to deQuilettes.

An increase of a few percent may not sound like much, but in the solar photovoltaic industry such improvements are highly sought after. “In the silicon photovoltaic industry, if you’re gaining half of a percent in efficiency, that’s worth hundreds of millions of dollars on the global market,” he says. A recent shift in silicon cell design, essentially adding a thin passivating layer and changing the doping profile, provides an efficiency gain of about half of a percent. As a result, “the whole industry is shifting and rapidly trying to push to get there.” The overall efficiency of silicon solar cells has only seen very small incremental improvements for the last 30 years, he says.

The record efficiencies for perovskites have mostly been set in controlled laboratory settings with small postage-stamp-size samples of the material. “Translating a record efficiency to commercial scale takes a long time,” deQuilettes says. “Another big hope is that with this understanding, people will be able to better engineer large areas to have these passivating effects.”

There are hundreds of different kinds of passivating salts and many different kinds of perovskites, so the basic understanding of the passivation process provided by this new work could help guide researchers to find even better combinations of materials, the researchers suggest. “There are so many different ways you could engineer the materials,” he says.

“I think we are on the doorstep of the first practical demonstrations of perovskites in the commercial applications,” Bulovic says. “And those first applications will be a far cry from what we’ll be able to do a few years from now.” He adds that perovskites “should not be seen as a displacement of silicon photovoltaics. It should be seen as an augmentation — yet another way to bring about more rapid deployment of solar electricity.”

“A lot of progress has been made in the last two years on finding surface treatments that improve perovskite solar cells,” says Michael McGehee, a professor of chemical engineering at the University of Colorado who was not associated with this research. “A lot of the research has been empirical with the mechanisms behind the improvements not being fully understood. This detailed study shows that treatments can not only passivate defects, but can also create a surface field that repels carriers that should be collected at the other side of the device. This understanding might help further improve the interfaces.”

The team included researchers at the Korea Research Institute of Chemical Technology, Cambridge University, the University of Washington in Seattle, and Sungkyunkwan University in Korea. The work was supported by the Tata Trust, the MIT Institute for Soldier Nanotechnologies, the U.S. Department of Energy, and the U.S. National Science Foundation.

Ever since she was an undergraduate student in Turkey, Simay Akar has been interested in renewable energy technology. As she progressed through her career after school, she chose not to develop the technology herself but to promote it. She has held marketing positions with major energy companies, and now she runs two startups.

One of Akar’s companies develops and manufactures lithium-ion batteries and recycles them. The other consults with businesses to help them achieve their sustainability goals.

Simay Akar

Employer

AK Energy Consulting

Title

CEO

Member grade

Senior member

Alma mater

Middle East Technical University in Ankara, Turkey

“I love the industry and the people in this business,” Akar says. “They are passionate about renewable energy and want their work to make a difference.”

Akar, a senior member, has become an active IEEE volunteer as well, holding leadership positions. First she served as student branch coordinator, then as a student chapter coordinator, and then as a member of several administrative bodies including the IEEE Young Professionals committee.

Akar received this year’s IEEE Theodore W. Hissey Outstanding Young Professional Award for her “leadership and inspiration of young professionals with significant contributions in the technical fields of photovoltaics and sustainable energy storage.” The award is sponsored by IEEE Young Professionals and the IEEE Photonics and Power & Energy societies.

Akar says she’s honored to get the award because “Theodore W. Hissey’s commitment to supporting young professionals across all of IEEE’s vast fields is truly commendable.” Hissey, who died in 2023, was an IEEE Life Fellow and IEEE director emeritus who supported the IEEE Young Professionals community for years.

“This award acknowledges the potential we hold to make a significant impact,” Akar says, “and it motivates me to keep pushing the boundaries in sustainable energy and inspire others to do the same.”

A career in sustainable technology

After graduating with a degree in the social impact of technology from Middle East Technical University, in Ankara, Turkey, Akar worked at several energy companies. Among them was Talesun Solar in Suzhou, China, where she was head of overseas marketing. She left to become the sales and marketing director for Eko Renewable Energy, in Istanbul.

In 2020 she founded Innoses in Shanghai. The company makes batteries for electric vehicles and customizes them for commercial, residential, and off-grid renewable energy systems such as solar panels. Additionally, Innoses recycles lithium-ion batteries, which otherwise end up in landfills, leaching hazardous chemicals.

“Recycling batteries helps cut down on pollution and greenhouse gas emissions,” Akar says. “That’s something we can all feel good about.”

She says there are two main methods of recycling batteries: melting and shredding.

Melting batteries is done by heating them until their parts separate. Valuable metals including cobalt and nickel are collected and cleaned to be reused in new batteries.

A shredding machine with high-speed rotating blades cuts batteries into small pieces. The different components are separated and treated with solutions to break them down further. Lithium, copper, and other metals are collected and cleaned to be reused.

The melting method tends to be better for collecting cobalt and nickel, while shredding is better for recovering lithium and copper, Akar says.

“This happens because each method focuses on different parts of the battery, so some metals are easier to extract depending on how they are processed,” she says. The chosen method depends on factors such as the composition of the batteries, the efficiency of the recycling process, and the desired metals to be recovered.

“There are a lot of environmental concerns related to battery usage,” Akar says. “But, if the right recycling process can be completed, batteries can also be sustainable. The right process could keep pollution and emissions low and protect the health of workers and surrounding communities.”

Akar worked at several energy companies including Talesun Solar in Suzhou, China, which manufactures solar cells like the one she is holding.Simay Akar

Helping businesses with sustainability

After noticing many businesses were struggling to become more sustainable, in 2021 Akar founded AK Energy Consulting in Istanbul. Through discussions with company leaders, she found they “need guidance and support from someone who understands not only sustainable technology but also the best way renewable energy can help the planet,” she says.

“My goal for the firm is simple: Be a force for change and create a future that’s sustainable and prosperous for everyone,” she says.

Akar and her staff meet with business leaders to better understand their sustainability goals. They identify areas where companies can improve, assess the impact the recommended changes can have, and research the latest sustainable technology. Her consulting firm also helps businesses understand how to meet government compliance regulations.

“By embracing sustainability, companies can create positive social, environmental, and economic impact while thriving in a rapidly changing world,” Akar says. “The best part of my job is seeing real change happen. Watching my clients switch to renewable energy, adopt eco-friendly practices, and hit their green goals is like a pat on the back.”

Serving on IEEE boards and committees

Akar has been a dedicated IEEE volunteer since joining the organization in 2007 as an undergraduate student and serving as chair of her school’s student branch. After graduating, she held other roles including Region 8 student branch coordinator, student chapter coordinator, and the region’s IEEE Women in Engineering committee chair.

In her nearly 20 years as a volunteer, Akar has been a member of several IEEE boards and committees including the Young Professionals committee, the Technical Activities Board, and the Nominations and Appointments Committee for top-level positions.

She is an active member of the IEEE Power & Energy Society and is a former IEEE PES liaison to the Women in Engineering committee. She is also a past vice chair of the society’s Women in Power group, which supports career advancement and education and provides networking opportunities.

“My volunteering experiences have helped me gain a deep understanding of how IEEE operates,” she says. “I’ve accumulated invaluable knowledge, and the work I’ve done has been incredibly fulfilling.”

As a member of the IEEE–Eta Kappa Nu honor society, Akar has mentored members of the next generation of technologists. She also served as a mentor in the IEEE Member and Geographic Activities Volunteer Leadership Training Program, which provides members with resources and an overview of IEEE, including its culture and mission. The program also offers participants training in management and leadership skills.

Akar says her experiences as an IEEE member have helped shape her career. When she transitioned from working as a marketer to being an entrepreneur, she joined IEEE Entrepreneurship, eventually serving as its vice chair of products. She also was chair of the Region 10 entrepreneurship committee.

“I had engineers I could talk to about emerging technologies and how to make a difference through Innoses,” she says. “I also received a lot of support from the group.”

Akar says she is committed to IEEE’s mission of advancing technology for humanity. She currently chairs the IEEE Humanitarian Technology Board’s best practices and projects committee. She also is chair of the IEEE MOVE global committee. The mobile outreach vehicle program provides communities affected by natural disasters with power and Internet access.

“Through my leadership,” Akar says, “I hope to contribute to the development of innovative solutions that improve the well-being of communities worldwide.”

Consider the dizzying ascent of solar energy in the United States: In the past decade, solar capacity increased nearly 900 percent, with electricity production eight times greater in 2023 than in 2014. The jump from 2022 to 2023 alone was 51 percent, with a record 32 gigawatts (GW) of solar installations coming online. In the past four years, more solar has been added to the grid than any other form of generation. Installed solar now tops 179 GW, enough to power nearly 33 million homes. The U.S. Department of Energy (DOE) is so bullish on the sun that its decarbonization plans envision solar satisfying 45 percent of the nation’s electricity demands by 2050.

But the continued rapid expansion of solar requires advances in technology, notably to improve the efficiency and durability of solar photovoltaic (PV) materials and manufacturing. That’s where Optigon, a three-year-old MIT spinout company, comes in.

“Our goal is to build tools for research and industry that can accelerate the energy transition,” says Dane deQuilettes, the company’s co-founder and chief science officer. “The technology we have developed for solar will enable measurements and analysis of materials as they are being made both in lab and on the manufacturing line, dramatically speeding up the optimization of PV.”

With roots in MIT’s vibrant solar research community, Optigon is poised for a 2024 rollout of technology it believes will drastically pick up the pace of solar power and other clean energy projects.

Beyond silicon

Silicon, the material mainstay of most PV, is limited by the laws of physics in the efficiencies it can achieve converting photons from the sun into electrical energy. Silicon-based solar cells can theoretically reach power conversion levels of just 30 percent, and real-world efficiency levels hover in the low 20s. But beyond the physical limitations of silicon, there is another issue at play for many researchers and the solar industry in the United States and elsewhere: China dominates the silicon PV market, from supply chains to manufacturing.

Scientists are eagerly pursuing alternative materials, either for enhancing silicon’s solar conversion capacity or for replacing silicon altogether.

In the past decade, a family of crystal-structured semiconductors known as perovskites has risen to the fore as a next-generation PV material candidate. Perovskite devices lend themselves to a novel manufacturing process using printing technology that could circumvent the supply chain juggernaut China has built for silicon. Perovskite solar cells can be stacked on each other or layered atop silicon PV, to achieve higher conversion efficiencies. Because perovskite technology is flexible and lightweight, modules can be used on roofs and other structures that cannot support heavier silicon PV, lowering costs and enabling a wider range of building-integrated solar devices.

But these new materials require testing, both during R&D and then on assembly lines, where missing or defective optical, electrical, or dimensional properties in the nano-sized crystal structures can negatively impact the end product.

“The actual measurement and data analysis processes have been really, really slow, because you have to use a bunch of separate tools that are all very manual,” says Optigon co-founder and chief executive officer Anthony Troupe ’21. “We wanted to come up with tools for automating detection of a material’s properties, for determining whether it could make a good or bad solar cell, and then for optimizing it.”

“Our approach packed several non-contact, optical measurements using different types of light sources and detectors into a single system, which together provide a holistic, cross-sectional view of the material,” says Brandon Motes ’21, ME ’22, co-founder and chief technical officer.

“This breakthrough in achieving millisecond timescales for data collection and analysis means we can take research-quality tools and actually put them on a full production system, getting extremely detailed information about products being built at massive, gigawatt scale in real-time,” says Troupe.

This streamlined system takes measurements “in the snap of the fingers, unlike the traditional tools,” says Joseph Berry, director of the US Manufacturing of Advanced Perovskites Consortium and a senior research scientist at the National Renewable Energy Laboratory. “Optigon’s techniques are high precision and allow high throughput, which means they can be used in a lot of contexts where you want rapid feedback and the ability to develop materials very, very quickly.”

According to Berry, Optigon’s technology may give the solar industry not just better materials, but the ability to pump out high-quality PV products at a brisker clip than is currently possible. “If Optigon is successful in deploying their technology, then we can more rapidly develop the materials that we need, manufacturing with the requisite precision again and again,” he says. “This could lead to the next generation of PV modules at a much, much lower cost.”

Measuring makes the difference

With Small Business Innovation Research funding from DOE to commercialize its products and a grant from the Massachusetts Clean Energy Center, Optigon has settled into a space at the climate technology incubator Greentown Labs in Somerville, Massachusetts. Here, the team is preparing for this spring’s launch of its first commercial product, whose genesis lies in MIT’s GridEdge Solar Research Program.

Led by Vladimir Bulović, a professor of electrical engineering and the director of MIT.nano, the GridEdge program was established with funding from the Tata Trusts to develop lightweight, flexible, and inexpensive solar cells for distribution to rural communities around the globe. When deQuilettes joined the group in 2017 as a postdoc, he was tasked with directing the program and building the infrastructure to study and make perovskite solar modules.

“We were trying to understand once we made the material whether or not it was good,” he recalls. “There were no good commercial metrology [the science of measurements] tools for materials beyond silicon, so we started to build our own.” Recognizing the group’s need for greater expertise on the problem, especially in the areas of electrical, software, and mechanical engineering, deQuilettes put a call out for undergraduate researchers to help build metrology tools for new solar materials.

“Forty people inquired, but when I met Brandon and Anthony, something clicked; it was clear we had a complementary skill set,” says deQuilettes. “We started working together, with Anthony coming up with beautiful designs to integrate multiple measurements, and Brandon creating boards to control all of the hardware, including different types of lasers. We started filing multiple patents and that was when we saw it all coming together.”

“We knew from the start that metrology could vastly improve not just materials, but production yields,” says Troupe. Adds deQuilettes, “Our goal was getting to the highest performance orders of magnitude faster than it would ordinarily take, so we developed tools that would not just be useful for research labs but for manufacturing lines to give live feedback on quality.”

The device Optigon designed for industry is the size of a football, “with sensor packages crammed into a tiny form factor, taking measurements as material flows directly underneath,” says Motes. “We have also thought carefully about ways to make interaction with this tool as seamless and, dare I say, as enjoyable as possible, streaming data to both a dashboard an operator can watch and to a custom database.”

Photovoltaics is just the start

The company may have already found its market niche. “A research group paid us to use our in-house prototype because they have such a burning need to get these sorts of measurements,” says Troupe, and according to Motes, “Potential customers ask us if they can buy the system now.” deQuilettes says, “Our hope is that we become the de facto company for doing any sort of characterization metrology in the United States and beyond.”

Challenges lie ahead for Optigon: product launches, full-scale manufacturing, technical assistance, and sales. Greentown Labs offers support, as does MIT’s own rich community of solar researchers and entrepreneurs. But the founders are already thinking about next phases.

“We are not limiting ourselves to the photovoltaics area,” says deQuilettes. “We’re planning on working in other clean energy materials such as batteries and fuel cells.”

That’s because the team wants to make the maximum impact on the climate challenge. “We’ve thought a lot about the potential our tools will have on reducing carbon emissions, and we’ve done a really in-depth analysis looking at how our system can increase production yields of solar panels and other energy technologies, reducing materials and energy wasted in conventional optimization,” deQuilettes says. “If we look across all these sectors, we can expect to offset about 1,000 million metric tons of CO₂ [carbon dioxide] per year in the not-too-distant future.”

The team has written scale into its business plan. “We want to be the key enabler for bringing these new energy technologies to market,” says Motes. “We envision being deployed on every manufacturing line making these types of materials. It’s our goal to walk around and know that if we see a solar panel deployed, there’s a pretty high likelihood that it will be one we measured at some point.”

Perovskites, a broad class of compounds with a particular kind of crystal structure, have long been seen as a promising alternative or supplement to today’s silicon or cadmium telluride solar panels. They could be far more lightweight and inexpensive, and could be coated onto virtually any substrate, including paper or flexible plastic that could be rolled up for easy transport.

In their efficiency at converting sunlight to electricity, perovskites are becoming comparable to silicon, whose manufacture still requires long, complex, and energy-intensive processes. One big remaining drawback is longevity: They tend to break down in a matter of months to years, while silicon solar panels can last more than two decades. And their efficiency over large module areas still lags behind silicon. Now, a team of researchers at MIT and several other institutions has revealed ways to optimize efficiency and better control degradation, by engineering the nanoscale structure of perovskite devices.

The study reveals new insights on how to make high-efficiency perovskite solar cells, and also provides new directions for engineers working to bring these solar cells to the commercial marketplace. The work is described today in the journal Nature Energy, in a paper by Dane deQuilettes, a recent MIT postdoc who is now co-founder and chief science officer of the MIT spinout Optigon, along with MIT professors Vladimir Bulovic and Moungi Bawendi, and 10 others at MIT and in Washington state, the U.K., and Korea.

“Ten years ago, if you had asked us what would be the ultimate solution to the rapid development of solar technologies, the answer would have been something that works as well as silicon but whose manufacturing is much simpler,” Bulovic says. “And before we knew it, the field of perovskite photovoltaics appeared. They were as efficient as silicon, and they were as easy to paint on as it is to paint on a piece of paper. The result was tremendous excitement in the field.”

Nonetheless, “there are some significant technical challenges of handling and managing this material in ways we’ve never done before,” he says. But the promise is so great that many hundreds of researchers around the world have been working on this technology. The new study looks at a very small but key detail: how to “passivate” the material’s surface, changing its properties in such a way that the perovskite no longer degrades so rapidly or loses efficiency.

“The key is identifying the chemistry of the interfaces, the place where the perovskite meets other materials,” Bulovic says, referring to the places where different materials are stacked next to perovskite in order to facilitate the flow of current through the device.

Engineers have developed methods for passivation, for example by using a solution that creates a thin passivating coating. But they’ve lacked a detailed understanding of how this process works — which is essential to make further progress in finding better coatings. The new study “addressed the ability to passivate those interfaces and elucidate the physics and science behind why this passivation works as well as it does,” Bulovic says.

The team used some of the most powerful instruments available at laboratories around the world to observe the interfaces between the perovskite layer and other materials, and how they develop, in unprecedented detail. This close examination of the passivation coating process and its effects resulted in “the clearest roadmap as of yet of what we can do to fine-tune the energy alignment at the interfaces of perovskites and neighboring materials,” and thus improve their overall performance, Bulovic says.

While the bulk of a perovskite material is in the form of a perfectly ordered crystalline lattice of atoms, this order breaks down at the surface. There may be extra atoms sticking out or vacancies where atoms are missing, and these defects cause losses in the material’s efficiency. That’s where the need for passivation comes in.

“This paper is essentially revealing a guidebook for how to tune surfaces, where a lot of these defects are, to make sure that energy is not lost at surfaces,” deQuilettes says. “It’s a really big discovery for the field,” he says. “This is the first paper that demonstrates how to systematically control and engineer surface fields in perovskites.”

The common passivation method is to bathe the surface in a solution of a salt called hexylammonium bromide, a technique developed at MIT several years ago by Jason Jungwan Yoo PhD ’20, who is a co-author of this paper, that led to multiple new world-record efficiencies. By doing that “you form a very thin layer on top of your defective surface, and that thin layer actually passivates a lot of the defects really well,” deQuilettes says. “And then the bromine, which is part of the salt, actually penetrates into the three-dimensional layer in a controllable way.” That penetration helps to prevent electrons from losing energy to defects at the surface.

These two effects, produced by a single processing step, produces the two beneficial changes simultaneously. “It’s really beautiful because usually you need to do that in two steps,” deQuilettes says.

The passivation reduces the energy loss of electrons at the surface after they have been knocked loose by sunlight. These losses reduce the overall efficiency of the conversion of sunlight to electricity, so reducing the losses boosts the net efficiency of the cells.

That could rapidly lead to improvements in the materials’ efficiency in converting sunlight to electricity, he says. The recent efficiency records for a single perovskite layer, several of them set at MIT, have ranged from about 24 to 26 percent, while the maximum theoretical efficiency that could be reached is about 30 percent, according to deQuilettes.

An increase of a few percent may not sound like much, but in the solar photovoltaic industry such improvements are highly sought after. “In the silicon photovoltaic industry, if you’re gaining half of a percent in efficiency, that’s worth hundreds of millions of dollars on the global market,” he says. A recent shift in silicon cell design, essentially adding a thin passivating layer and changing the doping profile, provides an efficiency gain of about half of a percent. As a result, “the whole industry is shifting and rapidly trying to push to get there.” The overall efficiency of silicon solar cells has only seen very small incremental improvements for the last 30 years, he says.

The record efficiencies for perovskites have mostly been set in controlled laboratory settings with small postage-stamp-size samples of the material. “Translating a record efficiency to commercial scale takes a long time,” deQuilettes says. “Another big hope is that with this understanding, people will be able to better engineer large areas to have these passivating effects.”

There are hundreds of different kinds of passivating salts and many different kinds of perovskites, so the basic understanding of the passivation process provided by this new work could help guide researchers to find even better combinations of materials, the researchers suggest. “There are so many different ways you could engineer the materials,” he says.

“I think we are on the doorstep of the first practical demonstrations of perovskites in the commercial applications,” Bulovic says. “And those first applications will be a far cry from what we’ll be able to do a few years from now.” He adds that perovskites “should not be seen as a displacement of silicon photovoltaics. It should be seen as an augmentation — yet another way to bring about more rapid deployment of solar electricity.”

“A lot of progress has been made in the last two years on finding surface treatments that improve perovskite solar cells,” says Michael McGehee, a professor of chemical engineering at the University of Colorado who was not associated with this research. “A lot of the research has been empirical with the mechanisms behind the improvements not being fully understood. This detailed study shows that treatments can not only passivate defects, but can also create a surface field that repels carriers that should be collected at the other side of the device. This understanding might help further improve the interfaces.”

The team included researchers at the Korea Research Institute of Chemical Technology, Cambridge University, the University of Washington in Seattle, and Sungkyunkwan University in Korea. The work was supported by the Tata Trust, the MIT Institute for Soldier Nanotechnologies, the U.S. Department of Energy, and the U.S. National Science Foundation.

Consider the dizzying ascent of solar energy in the United States: In the past decade, solar capacity increased nearly 900 percent, with electricity production eight times greater in 2023 than in 2014. The jump from 2022 to 2023 alone was 51 percent, with a record 32 gigawatts (GW) of solar installations coming online. In the past four years, more solar has been added to the grid than any other form of generation. Installed solar now tops 179 GW, enough to power nearly 33 million homes. The U.S. Department of Energy (DOE) is so bullish on the sun that its decarbonization plans envision solar satisfying 45 percent of the nation’s electricity demands by 2050.

But the continued rapid expansion of solar requires advances in technology, notably to improve the efficiency and durability of solar photovoltaic (PV) materials and manufacturing. That’s where Optigon, a three-year-old MIT spinout company, comes in.

“Our goal is to build tools for research and industry that can accelerate the energy transition,” says Dane deQuilettes, the company’s co-founder and chief science officer. “The technology we have developed for solar will enable measurements and analysis of materials as they are being made both in lab and on the manufacturing line, dramatically speeding up the optimization of PV.”

With roots in MIT’s vibrant solar research community, Optigon is poised for a 2024 rollout of technology it believes will drastically pick up the pace of solar power and other clean energy projects.

Beyond silicon

Silicon, the material mainstay of most PV, is limited by the laws of physics in the efficiencies it can achieve converting photons from the sun into electrical energy. Silicon-based solar cells can theoretically reach power conversion levels of just 30 percent, and real-world efficiency levels hover in the low 20s. But beyond the physical limitations of silicon, there is another issue at play for many researchers and the solar industry in the United States and elsewhere: China dominates the silicon PV market, from supply chains to manufacturing.

Scientists are eagerly pursuing alternative materials, either for enhancing silicon’s solar conversion capacity or for replacing silicon altogether.

In the past decade, a family of crystal-structured semiconductors known as perovskites has risen to the fore as a next-generation PV material candidate. Perovskite devices lend themselves to a novel manufacturing process using printing technology that could circumvent the supply chain juggernaut China has built for silicon. Perovskite solar cells can be stacked on each other or layered atop silicon PV, to achieve higher conversion efficiencies. Because perovskite technology is flexible and lightweight, modules can be used on roofs and other structures that cannot support heavier silicon PV, lowering costs and enabling a wider range of building-integrated solar devices.

But these new materials require testing, both during R&D and then on assembly lines, where missing or defective optical, electrical, or dimensional properties in the nano-sized crystal structures can negatively impact the end product.

“The actual measurement and data analysis processes have been really, really slow, because you have to use a bunch of separate tools that are all very manual,” says Optigon co-founder and chief executive officer Anthony Troupe ’21. “We wanted to come up with tools for automating detection of a material’s properties, for determining whether it could make a good or bad solar cell, and then for optimizing it.”

“Our approach packed several non-contact, optical measurements using different types of light sources and detectors into a single system, which together provide a holistic, cross-sectional view of the material,” says Brandon Motes ’21, ME ’22, co-founder and chief technical officer.

“This breakthrough in achieving millisecond timescales for data collection and analysis means we can take research-quality tools and actually put them on a full production system, getting extremely detailed information about products being built at massive, gigawatt scale in real-time,” says Troupe.

This streamlined system takes measurements “in the snap of the fingers, unlike the traditional tools,” says Joseph Berry, director of the US Manufacturing of Advanced Perovskites Consortium and a senior research scientist at the National Renewable Energy Laboratory. “Optigon’s techniques are high precision and allow high throughput, which means they can be used in a lot of contexts where you want rapid feedback and the ability to develop materials very, very quickly.”

According to Berry, Optigon’s technology may give the solar industry not just better materials, but the ability to pump out high-quality PV products at a brisker clip than is currently possible. “If Optigon is successful in deploying their technology, then we can more rapidly develop the materials that we need, manufacturing with the requisite precision again and again,” he says. “This could lead to the next generation of PV modules at a much, much lower cost.”

Measuring makes the difference

With Small Business Innovation Research funding from DOE to commercialize its products and a grant from the Massachusetts Clean Energy Center, Optigon has settled into a space at the climate technology incubator Greentown Labs in Somerville, Massachusetts. Here, the team is preparing for this spring’s launch of its first commercial product, whose genesis lies in MIT’s GridEdge Solar Research Program.

Led by Vladimir Bulović, a professor of electrical engineering and the director of MIT.nano, the GridEdge program was established with funding from the Tata Trusts to develop lightweight, flexible, and inexpensive solar cells for distribution to rural communities around the globe. When deQuilettes joined the group in 2017 as a postdoc, he was tasked with directing the program and building the infrastructure to study and make perovskite solar modules.

“We were trying to understand once we made the material whether or not it was good,” he recalls. “There were no good commercial metrology [the science of measurements] tools for materials beyond silicon, so we started to build our own.” Recognizing the group’s need for greater expertise on the problem, especially in the areas of electrical, software, and mechanical engineering, deQuilettes put a call out for undergraduate researchers to help build metrology tools for new solar materials.

“Forty people inquired, but when I met Brandon and Anthony, something clicked; it was clear we had a complementary skill set,” says deQuilettes. “We started working together, with Anthony coming up with beautiful designs to integrate multiple measurements, and Brandon creating boards to control all of the hardware, including different types of lasers. We started filing multiple patents and that was when we saw it all coming together.”

“We knew from the start that metrology could vastly improve not just materials, but production yields,” says Troupe. Adds deQuilettes, “Our goal was getting to the highest performance orders of magnitude faster than it would ordinarily take, so we developed tools that would not just be useful for research labs but for manufacturing lines to give live feedback on quality.”

The device Optigon designed for industry is the size of a football, “with sensor packages crammed into a tiny form factor, taking measurements as material flows directly underneath,” says Motes. “We have also thought carefully about ways to make interaction with this tool as seamless and, dare I say, as enjoyable as possible, streaming data to both a dashboard an operator can watch and to a custom database.”

Photovoltaics is just the start

The company may have already found its market niche. “A research group paid us to use our in-house prototype because they have such a burning need to get these sorts of measurements,” says Troupe, and according to Motes, “Potential customers ask us if they can buy the system now.” deQuilettes says, “Our hope is that we become the de facto company for doing any sort of characterization metrology in the United States and beyond.”

Challenges lie ahead for Optigon: product launches, full-scale manufacturing, technical assistance, and sales. Greentown Labs offers support, as does MIT’s own rich community of solar researchers and entrepreneurs. But the founders are already thinking about next phases.

“We are not limiting ourselves to the photovoltaics area,” says deQuilettes. “We’re planning on working in other clean energy materials such as batteries and fuel cells.”

That’s because the team wants to make the maximum impact on the climate challenge. “We’ve thought a lot about the potential our tools will have on reducing carbon emissions, and we’ve done a really in-depth analysis looking at how our system can increase production yields of solar panels and other energy technologies, reducing materials and energy wasted in conventional optimization,” deQuilettes says. “If we look across all these sectors, we can expect to offset about 1,000 million metric tons of CO₂ [carbon dioxide] per year in the not-too-distant future.”

The team has written scale into its business plan. “We want to be the key enabler for bringing these new energy technologies to market,” says Motes. “We envision being deployed on every manufacturing line making these types of materials. It’s our goal to walk around and know that if we see a solar panel deployed, there’s a pretty high likelihood that it will be one we measured at some point.”

Perovskites, a broad class of compounds with a particular kind of crystal structure, have long been seen as a promising alternative or supplement to today’s silicon or cadmium telluride solar panels. They could be far more lightweight and inexpensive, and could be coated onto virtually any substrate, including paper or flexible plastic that could be rolled up for easy transport.

In their efficiency at converting sunlight to electricity, perovskites are becoming comparable to silicon, whose manufacture still requires long, complex, and energy-intensive processes. One big remaining drawback is longevity: They tend to break down in a matter of months to years, while silicon solar panels can last more than two decades. And their efficiency over large module areas still lags behind silicon. Now, a team of researchers at MIT and several other institutions has revealed ways to optimize efficiency and better control degradation, by engineering the nanoscale structure of perovskite devices.

The study reveals new insights on how to make high-efficiency perovskite solar cells, and also provides new directions for engineers working to bring these solar cells to the commercial marketplace. The work is described today in the journal Nature Energy, in a paper by Dane deQuilettes, a recent MIT postdoc who is now co-founder and chief science officer of the MIT spinout Optigon, along with MIT professors Vladimir Bulovic and Moungi Bawendi, and 10 others at MIT and in Washington state, the U.K., and Korea.

“Ten years ago, if you had asked us what would be the ultimate solution to the rapid development of solar technologies, the answer would have been something that works as well as silicon but whose manufacturing is much simpler,” Bulovic says. “And before we knew it, the field of perovskite photovoltaics appeared. They were as efficient as silicon, and they were as easy to paint on as it is to paint on a piece of paper. The result was tremendous excitement in the field.”

Nonetheless, “there are some significant technical challenges of handling and managing this material in ways we’ve never done before,” he says. But the promise is so great that many hundreds of researchers around the world have been working on this technology. The new study looks at a very small but key detail: how to “passivate” the material’s surface, changing its properties in such a way that the perovskite no longer degrades so rapidly or loses efficiency.

“The key is identifying the chemistry of the interfaces, the place where the perovskite meets other materials,” Bulovic says, referring to the places where different materials are stacked next to perovskite in order to facilitate the flow of current through the device.

Engineers have developed methods for passivation, for example by using a solution that creates a thin passivating coating. But they’ve lacked a detailed understanding of how this process works — which is essential to make further progress in finding better coatings. The new study “addressed the ability to passivate those interfaces and elucidate the physics and science behind why this passivation works as well as it does,” Bulovic says.

The team used some of the most powerful instruments available at laboratories around the world to observe the interfaces between the perovskite layer and other materials, and how they develop, in unprecedented detail. This close examination of the passivation coating process and its effects resulted in “the clearest roadmap as of yet of what we can do to fine-tune the energy alignment at the interfaces of perovskites and neighboring materials,” and thus improve their overall performance, Bulovic says.

While the bulk of a perovskite material is in the form of a perfectly ordered crystalline lattice of atoms, this order breaks down at the surface. There may be extra atoms sticking out or vacancies where atoms are missing, and these defects cause losses in the material’s efficiency. That’s where the need for passivation comes in.

“This paper is essentially revealing a guidebook for how to tune surfaces, where a lot of these defects are, to make sure that energy is not lost at surfaces,” deQuilettes says. “It’s a really big discovery for the field,” he says. “This is the first paper that demonstrates how to systematically control and engineer surface fields in perovskites.”

The common passivation method is to bathe the surface in a solution of a salt called hexylammonium bromide, a technique developed at MIT several years ago by Jason Jungwan Yoo PhD ’20, who is a co-author of this paper, that led to multiple new world-record efficiencies. By doing that “you form a very thin layer on top of your defective surface, and that thin layer actually passivates a lot of the defects really well,” deQuilettes says. “And then the bromine, which is part of the salt, actually penetrates into the three-dimensional layer in a controllable way.” That penetration helps to prevent electrons from losing energy to defects at the surface.

These two effects, produced by a single processing step, produces the two beneficial changes simultaneously. “It’s really beautiful because usually you need to do that in two steps,” deQuilettes says.

The passivation reduces the energy loss of electrons at the surface after they have been knocked loose by sunlight. These losses reduce the overall efficiency of the conversion of sunlight to electricity, so reducing the losses boosts the net efficiency of the cells.

That could rapidly lead to improvements in the materials’ efficiency in converting sunlight to electricity, he says. The recent efficiency records for a single perovskite layer, several of them set at MIT, have ranged from about 24 to 26 percent, while the maximum theoretical efficiency that could be reached is about 30 percent, according to deQuilettes.

An increase of a few percent may not sound like much, but in the solar photovoltaic industry such improvements are highly sought after. “In the silicon photovoltaic industry, if you’re gaining half of a percent in efficiency, that’s worth hundreds of millions of dollars on the global market,” he says. A recent shift in silicon cell design, essentially adding a thin passivating layer and changing the doping profile, provides an efficiency gain of about half of a percent. As a result, “the whole industry is shifting and rapidly trying to push to get there.” The overall efficiency of silicon solar cells has only seen very small incremental improvements for the last 30 years, he says.

The record efficiencies for perovskites have mostly been set in controlled laboratory settings with small postage-stamp-size samples of the material. “Translating a record efficiency to commercial scale takes a long time,” deQuilettes says. “Another big hope is that with this understanding, people will be able to better engineer large areas to have these passivating effects.”

There are hundreds of different kinds of passivating salts and many different kinds of perovskites, so the basic understanding of the passivation process provided by this new work could help guide researchers to find even better combinations of materials, the researchers suggest. “There are so many different ways you could engineer the materials,” he says.

“I think we are on the doorstep of the first practical demonstrations of perovskites in the commercial applications,” Bulovic says. “And those first applications will be a far cry from what we’ll be able to do a few years from now.” He adds that perovskites “should not be seen as a displacement of silicon photovoltaics. It should be seen as an augmentation — yet another way to bring about more rapid deployment of solar electricity.”

“A lot of progress has been made in the last two years on finding surface treatments that improve perovskite solar cells,” says Michael McGehee, a professor of chemical engineering at the University of Colorado who was not associated with this research. “A lot of the research has been empirical with the mechanisms behind the improvements not being fully understood. This detailed study shows that treatments can not only passivate defects, but can also create a surface field that repels carriers that should be collected at the other side of the device. This understanding might help further improve the interfaces.”

The team included researchers at the Korea Research Institute of Chemical Technology, Cambridge University, the University of Washington in Seattle, and Sungkyunkwan University in Korea. The work was supported by the Tata Trust, the MIT Institute for Soldier Nanotechnologies, the U.S. Department of Energy, and the U.S. National Science Foundation.

The shift toward the electrification of vehicles and the expansion of the electrical grid for renewable energy integration has led to a considerable increase in the demand for power electronics devices and modernized cable systems — applications that will help ensure a consistent and long-term electricity supply. Simulation is used to drive the design of new power electronics devices (such as solar power and wind turbine systems), which are required to operate efficiently for varying levels of power production and power consumption (in the case of electric vehicles). A multiphysics modeling and simulation approach plays a critical role in meeting design goals and reducing the overall production time.

The COMSOL Multiphysics® software offers a wide range of capabilities for the modeling of energy transmission and power electronics, including quasistatic and time-harmonic electromagnetic fields. Additionally, the COMSOL® software features unique capabilities for coupling thermal and structural effects with electromagnetic fields. Effects such as induction heating and Joule heating, as well as structural stresses and strains caused by thermal expansion, can be studied with user-friendly modeling features.

In this webinar, we will provide an overview of the modeling and simulation functionality in the COMSOL® software for the design of high-power cables and devices for power electronics.

Register now for this free webinar!

Perovskites, a broad class of compounds with a particular kind of crystal structure, have long been seen as a promising alternative or supplement to today’s silicon or cadmium telluride solar panels. They could be far more lightweight and inexpensive, and could be coated onto virtually any substrate, including paper or flexible plastic that could be rolled up for easy transport.

In their efficiency at converting sunlight to electricity, perovskites are becoming comparable to silicon, whose manufacture still requires long, complex, and energy-intensive processes. One big remaining drawback is longevity: They tend to break down in a matter of months to years, while silicon solar panels can last more than two decades. And their efficiency over large module areas still lags behind silicon. Now, a team of researchers at MIT and several other institutions has revealed ways to optimize efficiency and better control degradation, by engineering the nanoscale structure of perovskite devices.

The study reveals new insights on how to make high-efficiency perovskite solar cells, and also provides new directions for engineers working to bring these solar cells to the commercial marketplace. The work is described today in the journal Nature Energy, in a paper by Dane deQuilettes, a recent MIT postdoc who is now co-founder and chief science officer of the MIT spinout Optigon, along with MIT professors Vladimir Bulovic and Moungi Bawendi, and 10 others at MIT and in Washington state, the U.K., and Korea.

“Ten years ago, if you had asked us what would be the ultimate solution to the rapid development of solar technologies, the answer would have been something that works as well as silicon but whose manufacturing is much simpler,” Bulovic says. “And before we knew it, the field of perovskite photovoltaics appeared. They were as efficient as silicon, and they were as easy to paint on as it is to paint on a piece of paper. The result was tremendous excitement in the field.”

Nonetheless, “there are some significant technical challenges of handling and managing this material in ways we’ve never done before,” he says. But the promise is so great that many hundreds of researchers around the world have been working on this technology. The new study looks at a very small but key detail: how to “passivate” the material’s surface, changing its properties in such a way that the perovskite no longer degrades so rapidly or loses efficiency.

“The key is identifying the chemistry of the interfaces, the place where the perovskite meets other materials,” Bulovic says, referring to the places where different materials are stacked next to perovskite in order to facilitate the flow of current through the device.

Engineers have developed methods for passivation, for example by using a solution that creates a thin passivating coating. But they’ve lacked a detailed understanding of how this process works — which is essential to make further progress in finding better coatings. The new study “addressed the ability to passivate those interfaces and elucidate the physics and science behind why this passivation works as well as it does,” Bulovic says.

The team used some of the most powerful instruments available at laboratories around the world to observe the interfaces between the perovskite layer and other materials, and how they develop, in unprecedented detail. This close examination of the passivation coating process and its effects resulted in “the clearest roadmap as of yet of what we can do to fine-tune the energy alignment at the interfaces of perovskites and neighboring materials,” and thus improve their overall performance, Bulovic says.

While the bulk of a perovskite material is in the form of a perfectly ordered crystalline lattice of atoms, this order breaks down at the surface. There may be extra atoms sticking out or vacancies where atoms are missing, and these defects cause losses in the material’s efficiency. That’s where the need for passivation comes in.

“This paper is essentially revealing a guidebook for how to tune surfaces, where a lot of these defects are, to make sure that energy is not lost at surfaces,” deQuilettes says. “It’s a really big discovery for the field,” he says. “This is the first paper that demonstrates how to systematically control and engineer surface fields in perovskites.”

The common passivation method is to bathe the surface in a solution of a salt called hexylammonium bromide, a technique developed at MIT several years ago by Jason Jungwan Yoo PhD ’20, who is a co-author of this paper, that led to multiple new world-record efficiencies. By doing that “you form a very thin layer on top of your defective surface, and that thin layer actually passivates a lot of the defects really well,” deQuilettes says. “And then the bromine, which is part of the salt, actually penetrates into the three-dimensional layer in a controllable way.” That penetration helps to prevent electrons from losing energy to defects at the surface.

These two effects, produced by a single processing step, produces the two beneficial changes simultaneously. “It’s really beautiful because usually you need to do that in two steps,” deQuilettes says.

The passivation reduces the energy loss of electrons at the surface after they have been knocked loose by sunlight. These losses reduce the overall efficiency of the conversion of sunlight to electricity, so reducing the losses boosts the net efficiency of the cells.

That could rapidly lead to improvements in the materials’ efficiency in converting sunlight to electricity, he says. The recent efficiency records for a single perovskite layer, several of them set at MIT, have ranged from about 24 to 26 percent, while the maximum theoretical efficiency that could be reached is about 30 percent, according to deQuilettes.

An increase of a few percent may not sound like much, but in the solar photovoltaic industry such improvements are highly sought after. “In the silicon photovoltaic industry, if you’re gaining half of a percent in efficiency, that’s worth hundreds of millions of dollars on the global market,” he says. A recent shift in silicon cell design, essentially adding a thin passivating layer and changing the doping profile, provides an efficiency gain of about half of a percent. As a result, “the whole industry is shifting and rapidly trying to push to get there.” The overall efficiency of silicon solar cells has only seen very small incremental improvements for the last 30 years, he says.

The record efficiencies for perovskites have mostly been set in controlled laboratory settings with small postage-stamp-size samples of the material. “Translating a record efficiency to commercial scale takes a long time,” deQuilettes says. “Another big hope is that with this understanding, people will be able to better engineer large areas to have these passivating effects.”

There are hundreds of different kinds of passivating salts and many different kinds of perovskites, so the basic understanding of the passivation process provided by this new work could help guide researchers to find even better combinations of materials, the researchers suggest. “There are so many different ways you could engineer the materials,” he says.

“I think we are on the doorstep of the first practical demonstrations of perovskites in the commercial applications,” Bulovic says. “And those first applications will be a far cry from what we’ll be able to do a few years from now.” He adds that perovskites “should not be seen as a displacement of silicon photovoltaics. It should be seen as an augmentation — yet another way to bring about more rapid deployment of solar electricity.”

“A lot of progress has been made in the last two years on finding surface treatments that improve perovskite solar cells,” says Michael McGehee, a professor of chemical engineering at the University of Colorado who was not associated with this research. “A lot of the research has been empirical with the mechanisms behind the improvements not being fully understood. This detailed study shows that treatments can not only passivate defects, but can also create a surface field that repels carriers that should be collected at the other side of the device. This understanding might help further improve the interfaces.”

The team included researchers at the Korea Research Institute of Chemical Technology, Cambridge University, the University of Washington in Seattle, and Sungkyunkwan University in Korea. The work was supported by the Tata Trust, the MIT Institute for Soldier Nanotechnologies, the U.S. Department of Energy, and the U.S. National Science Foundation.

Perovskites, a broad class of compounds with a particular kind of crystal structure, have long been seen as a promising alternative or supplement to today’s silicon or cadmium telluride solar panels. They could be far more lightweight and inexpensive, and could be coated onto virtually any substrate, including paper or flexible plastic that could be rolled up for easy transport.

In their efficiency at converting sunlight to electricity, perovskites are becoming comparable to silicon, whose manufacture still requires long, complex, and energy-intensive processes. One big remaining drawback is longevity: They tend to break down in a matter of months to years, while silicon solar panels can last more than two decades. And their efficiency over large module areas still lags behind silicon. Now, a team of researchers at MIT and several other institutions has revealed ways to optimize efficiency and better control degradation, by engineering the nanoscale structure of perovskite devices.

The study reveals new insights on how to make high-efficiency perovskite solar cells, and also provides new directions for engineers working to bring these solar cells to the commercial marketplace. The work is described today in the journal Nature Energy, in a paper by Dane deQuilettes, a recent MIT postdoc who is now co-founder and chief science officer of the MIT spinout Optigon, along with MIT professors Vladimir Bulovic and Moungi Bawendi, and 10 others at MIT and in Washington state, the U.K., and Korea.

“Ten years ago, if you had asked us what would be the ultimate solution to the rapid development of solar technologies, the answer would have been something that works as well as silicon but whose manufacturing is much simpler,” Bulovic says. “And before we knew it, the field of perovskite photovoltaics appeared. They were as efficient as silicon, and they were as easy to paint on as it is to paint on a piece of paper. The result was tremendous excitement in the field.”

Nonetheless, “there are some significant technical challenges of handling and managing this material in ways we’ve never done before,” he says. But the promise is so great that many hundreds of researchers around the world have been working on this technology. The new study looks at a very small but key detail: how to “passivate” the material’s surface, changing its properties in such a way that the perovskite no longer degrades so rapidly or loses efficiency.

“The key is identifying the chemistry of the interfaces, the place where the perovskite meets other materials,” Bulovic says, referring to the places where different materials are stacked next to perovskite in order to facilitate the flow of current through the device.

Engineers have developed methods for passivation, for example by using a solution that creates a thin passivating coating. But they’ve lacked a detailed understanding of how this process works — which is essential to make further progress in finding better coatings. The new study “addressed the ability to passivate those interfaces and elucidate the physics and science behind why this passivation works as well as it does,” Bulovic says.

The team used some of the most powerful instruments available at laboratories around the world to observe the interfaces between the perovskite layer and other materials, and how they develop, in unprecedented detail. This close examination of the passivation coating process and its effects resulted in “the clearest roadmap as of yet of what we can do to fine-tune the energy alignment at the interfaces of perovskites and neighboring materials,” and thus improve their overall performance, Bulovic says.

While the bulk of a perovskite material is in the form of a perfectly ordered crystalline lattice of atoms, this order breaks down at the surface. There may be extra atoms sticking out or vacancies where atoms are missing, and these defects cause losses in the material’s efficiency. That’s where the need for passivation comes in.

“This paper is essentially revealing a guidebook for how to tune surfaces, where a lot of these defects are, to make sure that energy is not lost at surfaces,” deQuilettes says. “It’s a really big discovery for the field,” he says. “This is the first paper that demonstrates how to systematically control and engineer surface fields in perovskites.”

The common passivation method is to bathe the surface in a solution of a salt called hexylammonium bromide, a technique developed at MIT several years ago by Jason Jungwan Yoo PhD ’20, who is a co-author of this paper, that led to multiple new world-record efficiencies. By doing that “you form a very thin layer on top of your defective surface, and that thin layer actually passivates a lot of the defects really well,” deQuilettes says. “And then the bromine, which is part of the salt, actually penetrates into the three-dimensional layer in a controllable way.” That penetration helps to prevent electrons from losing energy to defects at the surface.

These two effects, produced by a single processing step, produces the two beneficial changes simultaneously. “It’s really beautiful because usually you need to do that in two steps,” deQuilettes says.

The passivation reduces the energy loss of electrons at the surface after they have been knocked loose by sunlight. These losses reduce the overall efficiency of the conversion of sunlight to electricity, so reducing the losses boosts the net efficiency of the cells.

That could rapidly lead to improvements in the materials’ efficiency in converting sunlight to electricity, he says. The recent efficiency records for a single perovskite layer, several of them set at MIT, have ranged from about 24 to 26 percent, while the maximum theoretical efficiency that could be reached is about 30 percent, according to deQuilettes.

An increase of a few percent may not sound like much, but in the solar photovoltaic industry such improvements are highly sought after. “In the silicon photovoltaic industry, if you’re gaining half of a percent in efficiency, that’s worth hundreds of millions of dollars on the global market,” he says. A recent shift in silicon cell design, essentially adding a thin passivating layer and changing the doping profile, provides an efficiency gain of about half of a percent. As a result, “the whole industry is shifting and rapidly trying to push to get there.” The overall efficiency of silicon solar cells has only seen very small incremental improvements for the last 30 years, he says.

The record efficiencies for perovskites have mostly been set in controlled laboratory settings with small postage-stamp-size samples of the material. “Translating a record efficiency to commercial scale takes a long time,” deQuilettes says. “Another big hope is that with this understanding, people will be able to better engineer large areas to have these passivating effects.”

There are hundreds of different kinds of passivating salts and many different kinds of perovskites, so the basic understanding of the passivation process provided by this new work could help guide researchers to find even better combinations of materials, the researchers suggest. “There are so many different ways you could engineer the materials,” he says.

“I think we are on the doorstep of the first practical demonstrations of perovskites in the commercial applications,” Bulovic says. “And those first applications will be a far cry from what we’ll be able to do a few years from now.” He adds that perovskites “should not be seen as a displacement of silicon photovoltaics. It should be seen as an augmentation — yet another way to bring about more rapid deployment of solar electricity.”

“A lot of progress has been made in the last two years on finding surface treatments that improve perovskite solar cells,” says Michael McGehee, a professor of chemical engineering at the University of Colorado who was not associated with this research. “A lot of the research has been empirical with the mechanisms behind the improvements not being fully understood. This detailed study shows that treatments can not only passivate defects, but can also create a surface field that repels carriers that should be collected at the other side of the device. This understanding might help further improve the interfaces.”

The team included researchers at the Korea Research Institute of Chemical Technology, Cambridge University, the University of Washington in Seattle, and Sungkyunkwan University in Korea. The work was supported by the Tata Trust, the MIT Institute for Soldier Nanotechnologies, the U.S. Department of Energy, and the U.S. National Science Foundation.

It’s late in the afternoon of 2 April 2023 on the island of Kauai. The sun is sinking over this beautiful and peaceful place, when, suddenly, at 4:25 pm, there’s a glitch: The largest generator on the island, a 26-megawatt oil-fired turbine, goes offline.

This is a more urgent problem than it might sound. The westernmost Hawaiian island of significant size, Kauai is home to around 70,000 residents and 30,000 tourists at any given time. Renewable energy accounts for 70 percent of the energy produced in a typical year—a proportion that’s among the highest in the world and that can be hard to sustain for such a small and isolated grid. During the day, the local system operator, the Kauai Island Utility Cooperative, sometimes reaches levels of 90 percent from solar alone. But on 2 April, the 26-MW generator was running near its peak output, to compensate for the drop in solar output as the sun set. At the moment when it failed, that single generator had been supplying 60 percent of the load for the entire island, with the rest being met by a mix of smaller generators and several utility-scale solar-and-battery systems.

Normally, such a sudden loss would spell disaster for a small, islanded grid. But the Kauai grid has a feature that many larger grids lack: a technology called grid-forming inverters. An inverter converts direct-current electricity to grid-compatible alternating current. The island’s grid-forming inverters are connected to those battery systems, and they are a special type—in fact, they had been installed with just such a contingency in mind. They improve the grid’s resilience and allow it to operate largely on resources like batteries, solar photovoltaics, and wind turbines, all of which connect to the grid through inverters. On that April day in 2023, Kauai had over 150 megawatt-hours’ worth of energy stored in batteries—and also the grid-forming inverters necessary to let those batteries respond rapidly and provide stable power to the grid. They worked exactly as intended and kept the grid going without any blackouts.

The photovoltaic panels at the Kapaia solar-plus-storage facility, operated by the Kauai Island Utility Cooperative in Hawaii, are capable of generating 13 megawatts under ideal conditions.TESLA

A solar-plus-storage facility at the U.S. Navy’s Pacific Missile Range Facility, in the southwestern part of Kauai, is one of two on the island equipped with grid-forming inverters. U.S. NAVY

That April event in Kauai offers a preview of the electrical future, especially for places where utilities are now, or soon will be, relying heavily on solar photovoltaic or wind power. Similar inverters have operated for years within smaller off-grid installations. However, using them in a multimegawatt power grid, such as Kauai’s, is a relatively new idea. And it’s catching on fast: At the time of this writing, at least eight major grid-forming projects are either under construction or in operation in Australia, along with others in Asia, Europe, North America, and the Middle East.

Reaching net-zero-carbon emissions by 2050, as many international organizations now insist is necessary to stave off dire climate consequences, will require a rapid and massive shift in electricity-generating infrastructures. The International Energy Agency has calculated that to have any hope of achieving this goal would require the addition, every year, of 630 gigawatts of solar photovoltaics and 390 GW of wind starting no later than 2030—figures that are around four times as great as than any annual tally so far.

The only economical way to integrate such high levels of renewable energy into our grids is with grid-forming inverters, which can be implemented on any technology that uses an inverter, including wind, solar photovoltaics, batteries, fuel cells, microturbines, and even high-voltage direct-current transmission lines. Grid-forming inverters for utility-scale batteries are available today from Tesla, GPTech, SMA, GE Vernova, EPC Power, Dynapower, Hitachi, Enphase, CE+T, and others. Grid-forming converters for HVDC, which convert high-voltage direct current to alternating current and vice versa, are also commercially available, from companies including Hitachi, Siemens, and GE Vernova. For photovoltaics and wind, grid-forming inverters are not yet commercially available at the size and scale needed for large grids, but they are now being developed by GE Vernova, Enphase, and Solectria.

The Grid Depends on Inertia

To understand the promise of grid-forming inverters, you must first grasp how our present electrical grid functions, and why it’s inadequate for a future dominated by renewable resources such as solar and wind power.

Conventional power plants that run on natural gas, coal, nuclear fuel, or hydropower produce electricity with synchronous generators—large rotating machines that produce AC electricity at a specified frequency and voltage. These generators have some physical characteristics that make them ideal for operating power grids. Among other things, they have a natural tendency to synchronize with one another, which helps make it possible to restart a grid that’s completely blacked out. Most important, a generator has a large rotating mass, namely its rotor. When a synchronous generator is spinning, its rotor, which can weigh well over 100 tonnes, cannot stop quickly.

The Kauai electric transmission grid operates at 57.1 kilovolts, an unusual voltage that is a legacy from the island’s sugar-plantation era. The network has grid-forming inverters at the Pacific Missile Range Facility, in the southwest, and at Kapaia, in the southeast. CHRIS PHILPOT

This characteristic gives rise to a property called system inertia. It arises naturally from those large generators running in synchrony with one another. Over many years, engineers used the inertia characteristics of the grid to determine how fast a power grid will change its frequency when a failure occurs, and then developed mitigation procedures based on that information.

If one or more big generators disconnect from the grid, the sudden imbalance of load to generation creates torque that extracts rotational energy from the remaining synchronous machines, slowing them down and thereby reducing the grid frequency—the frequency is electromechanically linked to the rotational speed of the generators feeding the grid. Fortunately, the kinetic energy stored in all that rotating mass slows this frequency drop and typically allows the remaining generators enough time to ramp up their power output to meet the additional load.

Electricity grids are designed so that even if the network loses its largest generator, running at full output, the other generators can pick up the additional load and the frequency nadir never falls below a specific threshold. In the United States, where nominal grid frequency is 60 hertz, the threshold is generally between 59.3 and 59.5 Hz. As long as the frequency remains above this point, local blackouts are unlikely to occur.

Why We Need Grid-Forming Inverters

Wind turbines, photovoltaics, and battery-storage systems differ from conventional generators because they all produce direct current (DC) electricity—they don’t have a heartbeat like alternating current does. With the exception of wind turbines, these are not rotating machines. And most modern wind turbines aren’t synchronously rotating machines from a grid standpoint—the frequency of their AC output depends on the wind speed. So that variable-frequency AC is rectified to DC before being converted to an AC waveform that matches the grid’s.

As mentioned, inverters convert the DC electricity to grid-compatible AC. A conventional, or grid-following, inverter uses power transistors that repeatedly and rapidly switch the polarity applied to a load. By switching at high speed, under software control, the inverter produces a high-frequency AC signal that is filtered by capacitors and other components to produce a smooth AC current output. So in this scheme, the software shapes the output waveform. In contrast, with synchronous generators the output waveform is determined by the physical and electrical characteristics of the generator.

Grid-following inverters operate only if they can “see” an existing voltage and frequency on the grid that they can synchronize to. They rely on controls that sense the frequency of the voltage waveform and lock onto that signal, usually by means of a technology called a phase-locked loop. So if the grid goes down, these inverters will stop injecting power because there is no voltage to follow. A key point here is that grid-following inverters do not deliver any inertia.

Przemyslaw Koralewicz, David Corbus, Shahil Shah, and Robb Wallen, researchers at the National Renewable Energy Laboratory, evaluate a grid-forming inverter used on Kauai at the NREL Flatirons Campus. DENNIS SCHROEDER/NREL

Grid-following inverters work fine when inverter-based power sources are relatively scarce. But as the levels of inverter-based resources rise above 60 to 70 percent, things start to get challenging. That’s why system operators around the world are beginning to put the brakes on renewable deployment and curtailing the operation of existing renewable plants. For example, the Electric Reliability Council of Texas (ERCOT) regularly curtails the use of renewables in that state because of stability issues arising from too many grid-following inverters.

It doesn’t have to be this way. When the level of inverter-based power sources on a grid is high, the inverters themselves could support grid-frequency stability. And when the level is very high, they could form the voltage and frequency of the grid. In other words, they could collectively set the pulse, rather than follow it. That’s what grid-forming inverters do.

The Difference Between Grid Forming and Grid Following

Grid-forming (GFM) and grid-following (GFL) inverters share several key characteristics. Both can inject current into the grid during a disturbance. Also, both types of inverters can support the voltage on a grid by controlling their reactive power, which is the product of the voltage and the current that are out of phase with each other. Both kinds of inverters can also help prop up the frequency on the grid, by controlling their active power, which is the product of the voltage and current that are in phase with each other.

What makes grid-forming inverters different from grid-following inverters is mainly software. GFM inverters are controlled by code designed to maintain a stable output voltage waveform, but they also allow the magnitude and phase of that waveform to change over time. What does that mean in practice? The unifying characteristic of all GFM inverters is that they hold a constant voltage magnitude and frequency on short timescales—for example, a few dozen milliseconds—while allowing that waveform’s magnitude and frequency to change over several seconds to synchronize with other nearby sources, such as traditional generators and other GFM inverters.

Some GFM inverters, called virtual synchronous machines, achieve this response by mimicking the physical and electrical characteristics of a synchronous generator, using control equations that describe how it operates. Other GFM inverters are programmed to simply hold a constant target voltage and frequency, allowing that target voltage and frequency to change slowly over time to synchronize with the rest of the power grid following what is called a droop curve. A droop curve is a formula used by grid operators to indicate how a generator should respond to a deviation from nominal voltage or frequency on its grid. There are many variations of these two basic GFM control methods, and other methods have been proposed as well.

At least eight major grid-forming projects are either under construction or in operation in Australia, along with others in Asia, Europe, North America, and the Middle East.

To better understand this concept, imagine that a transmission line shorts to ground or a generator trips due to a lightning strike. (Such problems typically occur multiple times a week, even on the best-run grids.) The key advantage of a GFM inverter in such a situation is that it does not need to quickly sense frequency and voltage decline on the grid to respond. Instead, a GFM inverter just holds its own voltage and frequency relatively constant by injecting whatever current is needed to achieve that, subject to its physical limits. In other words, a GFM inverter is programmed to act like an AC voltage source behind some small impedance (impedance is the opposition to AC current arising from resistance, capacitance, and inductance). In response to an abrupt drop in grid voltage, its digital controller increases current output by allowing more current to pass through its power transistors, without even needing to measure the change it’s responding to. In response to falling grid frequency, the controller increases power.

GFL controls, on the other hand, need to first measure the change in voltage or frequency, and then take an appropriate control action before adjusting their output current to mitigate the change. This GFL strategy works if the response does not need to be superfast (as in microseconds). But as the grid becomes weaker (meaning there are fewer voltage sources nearby), GFL controls tend to become unstable. That’s because by the time they measure the voltage and adjust their output, the voltage has already changed significantly, and fast injection of current at that point can potentially lead to a dangerous positive feedback loop. Adding more GFL inverters also tends to reduce stability because it becomes more difficult for the remaining voltage sources to stabilize them all.

When a GFM inverter responds with a surge in current, it must do so within tightly prescribed limits. It must inject enough current to provide some stability but not enough to damage the power transistors that control the current flow.

Increasing the maximum current flow is possible, but it requires increasing the capacity of the power transistors and other components, which can significantly increase cost. So most inverters (both GFM and GFL) don’t provide current surges larger than about 10 to 30 percent above their rated steady-state current. For comparison, a synchronous generator can inject around 500 to 700 percent more than its rated current for several AC line cycles (around a tenth of a second, say) without sustaining any damage. For a large generator, this can amount to thousands of amperes. Because of this difference between inverters and synchronous generators, the protection technologies used in power grids will need to be adjusted to account for lower levels of fault current.

What the Kauai Episode Reveals

The 2 April event on Kauai offered an unusual opportunity to study the performance of GFM inverters during a disturbance. After the event, one of us (Andy Hoke) along with Jin Tan and Shuan Dong and some coworkers at the National Renewable Energy Laboratory, collaborated with the Kauai Island Utility Cooperative (KIUC) to get a clear understanding of how the remaining system generators and inverter-based resources interacted with each other during the disturbance. What we determined will help power grids of the future operate at levels of inverter-based resources up to 100 percent.

NREL researchers started by creating a model of the Kauai grid. We then used a technique called electromagnetic transient (EMT) simulation, which yields information on the AC waveforms on a sub-millisecond basis. In addition, we conducted hardware tests at NREL’s Flatirons Campus on a scaled-down replica of one of Kauai’s solar-battery plants, to evaluate the grid-forming control algorithms for inverters deployed on the island.The leap from power systems like Kauai’s, with a peak demand of roughly 80 MW, to ones like South Australia’s, at 3,000 MW, is a big one. But it’s nothing compared to what will come next: grids with peak demands of 85,000 MW (in Texas) and 742,000 MW (the rest of the continental United States).

Several challenges need to be solved before we can attempt such leaps. They include creating standard GFM specifications so that inverter vendors can create products. We also need accurate models that can be used to simulate the performance of GFM inverters, so we can understand their impact on the grid.

Some progress in standardization is already happening. In the United States, for example, the North American Electric Reliability Corporation (NERC) recently published a recommendation that all future large-scale battery-storage systems have grid-forming capability.

Standards for GFM performance and validation are also starting to emerge in some countries, including Australia, Finland, and Great Britain. In the United States, the Department of Energy recently backed a consortium to tackle building and integrating inverter-based resources into power grids. Led by the National Renewable Energy Laboratory, the University of Texas at Austin, and the Electric Power Research Institute, the Universal Interoperability for Grid-Forming Inverters (UNIFI) Consortium aims to address the fundamental challenges in integrating very high levels of inverter-based resources with synchronous generators in power grids. The consortium now has over 30 members from industry, academia, and research laboratories.

A recording of the frequency responses to two different grid disruptions on Kauai shows the advantages of grid-forming inverters. The red trace shows the relatively contained response with two grid-forming inverter systems in operation. The blue trace shows the more extreme response to an earlier, comparable disruption, at a time when there was only one grid-forming plant online.NATIONAL RENEWABLE ENERGY LABORATORY

At 4:25 pm on 2 April, there were two large GFM solar-battery plants, one large GFL solar-battery plant, one large oil-fired turbine, one small diesel plant, two small hydro plants, one small biomass plant, and a handful of other solar generators online. Immediately after the oil-fired turbine failed, the AC frequency dropped quickly from 60 Hz to just above 59 Hz during the first 3 seconds [red trace in the figure above]. As the frequency dropped, the two GFM-equipped plants quickly ramped up power, with one plant quadrupling its output and the other doubling its output in less than 1/20 of a second.

In contrast, the remaining synchronous machines contributed some rapid but unsustained active power via their inertial responses, but took several seconds to produce sustained increases in their output. It is safe to say, and it has been confirmed through EMT simulation, that without the two GFM plants, the entire grid would have experienced a blackout.

Coincidentally, an almost identical generator failure had occurred a couple of years earlier, on 21 November 2021. In this case, only one solar-battery plant had grid-forming inverters. As in the 2023 event, the three large solar-battery plants quickly ramped up power and prevented a blackout. However, the frequency and voltage throughout the grid began to oscillate around 20 times per second [the blue trace in the figure above], indicating a major grid stability problem and causing some customers to be automatically disconnected. NREL’s EMT simulations, hardware tests, and controls analysis all confirmed that the severe oscillation was due to a combination of grid-following inverters tuned for extremely fast response and a lack of sufficient grid strength to support those GFL inverters.

In other words, the 2021 event illustrates how too many conventional GFL inverters can erode stability. Comparing the two events demonstrates the value of GFM inverter controls—not just to provide fast yet stable responses to grid events but also to stabilize nearby GFL inverters and allow the entire grid to maintain operations without a blackout.

Australia Commissions Big GFM Projects

In sunny South Australia, solar power now routinely supplies all or nearly all of the power needed during the middle of the day. Shown here is the chart for 31 December 2023, in which solar supplied slightly more power than the state needed at around 1:30 p.m. AUSTRALIAN ENERGY MARKET OPERATOR (AEMO)

The next step for inverter-dominated power grids is to go big. Some of the most important deployments are in South Australia. As in Kauai, the South Australian grid now has such high levels of solar generation that it regularly experiences days in which the solar generation can exceed the peak demand during the middle of the day [see figure at left].

The most well-known of the GFM resources in Australia is the Hornsdale Power Reserve in South Australia. This 150-MW/194-MWh system, which uses Tesla’s Powerpack 2 lithium-ion batteries, was originally installed in 2017 and was upgraded to grid-forming capability in 2020.

Australia’s largest battery (500 MW/1,000 MWh) with grid-forming inverters is expected to start operating in Liddell, New South Wales, later this year. This battery, from AGL Energy, will be located at the site of a decommissioned coal plant. This and several other larger GFM systems are expected to start working on the South Australia grid over the next year.

The leap from power systems like Kauai’s, with a peak demand of roughly 80 MW, to ones like South Australia’s, at 3,000 MW, is a big one. But it’s nothing compared to what will come next: grids with peak demands of 85,000 MW (in Texas) and 742,000 MW (the rest of the continental United States).

Several challenges need to be solved before we can attempt such leaps. They include creating standard GFM specifications so that inverter vendors can create products. We also need accurate models that can be used to simulate the performance of GFM inverters, so we can understand their impact on the grid.

Some progress in standardization is already happening. In the United States, for example, the North American Electric Reliability Corporation (NERC) recently published a recommendation that all future large-scale battery-storage systems have grid-forming capability.

Standards for GFM performance and validation are also starting to emerge in some countries, including Australia, Finland, and Great Britain. In the United States, the Department of Energy recently backed a consortium to tackle building and integrating inverter-based resources into power grids. Led by the National Renewable Energy Laboratory, the University of Texas at Austin, and the Electric Power Research Institute, the Universal Interoperability for Grid-Forming Inverters (UNIFI) Consortium aims to address the fundamental challenges in integrating very high levels of inverter-based resources with synchronous generators in power grids. The consortium now has over 30 members from industry, academia, and research laboratories.

One of Australia’s major energy-storage facilities is the Hornsdale Power Reserve, at 150 megawatts and 194 megawatt-hours. Hornsdale, along with another facility called the Riverina Battery, are the country’s two largest grid-forming installations. NEOEN

In addition to specifications, we need computer models of GFM inverters to verify their performance in large-scale systems. Without such verification, grid operators won’t trust the performance of new GFM technologies. Using GFM models built by the UNIFI Consortium, system operators and utilities such as the Western Electricity Coordinating Council, American Electric Power, and ERCOT (the Texas’s grid-reliability organization) are conducting studies to understand how GFM technology can help their grids.

Getting to a Greener Grid

As we progress toward a future grid dominated by inverter-based generation, a question naturally arises: Will all inverters need to be grid-forming? No. Several studies and simulations have indicated that we’ll need just enough GFM inverters to strengthen each area of the grid so that nearby GFL inverters remain stable.

How many GFMs is that? The answer depends on the characteristics of the grid and other generators. Some initial studies have shown that a power system can operate with 100 percent inverter-based resources if around 30 percent are grid-forming. More research is needed to understand how that number depends on details such as the grid topology and the control details of both the GFLs and the GFMs.

Ultimately, though, electricity generation that is completely carbon free in its operation is within our grasp. Our challenge now is to make the leap from small to large to very large systems. We know what we have to do, and it will not require technologies that are far more advanced than what we already have. It will take testing, validation in real-world scenarios, and standardization so that synchronous generators and inverters can unify their operations to create a reliable and robust power grid. Manufacturers, utilities, and regulators will have to work together to make this happen rapidly and smoothly. Only then can we begin the next stage of the grid’s evolution, to large-scale systems that are truly carbon neutral.

Perovskites, a broad class of compounds with a particular kind of crystal structure, have long been seen as a promising alternative or supplement to today’s silicon or cadmium telluride solar panels. They could be far more lightweight and inexpensive, and could be coated onto virtually any substrate, including paper or flexible plastic that could be rolled up for easy transport.

In their efficiency at converting sunlight to electricity, perovskites are becoming comparable to silicon, whose manufacture still requires long, complex, and energy-intensive processes. One big remaining drawback is longevity: They tend to break down in a matter of months to years, while silicon solar panels can last more than two decades. And their efficiency over large module areas still lags behind silicon. Now, a team of researchers at MIT and several other institutions has revealed ways to optimize efficiency and better control degradation, by engineering the nanoscale structure of perovskite devices.

The study reveals new insights on how to make high-efficiency perovskite solar cells, and also provides new directions for engineers working to bring these solar cells to the commercial marketplace. The work is described today in the journal Nature Energy, in a paper by Dane deQuilettes, a recent MIT postdoc who is now co-founder and chief science officer of the MIT spinout Optigon, along with MIT professors Vladimir Bulovic and Moungi Bawendi, and 10 others at MIT and in Washington state, the U.K., and Korea.

“Ten years ago, if you had asked us what would be the ultimate solution to the rapid development of solar technologies, the answer would have been something that works as well as silicon but whose manufacturing is much simpler,” Bulovic says. “And before we knew it, the field of perovskite photovoltaics appeared. They were as efficient as silicon, and they were as easy to paint on as it is to paint on a piece of paper. The result was tremendous excitement in the field.”

Nonetheless, “there are some significant technical challenges of handling and managing this material in ways we’ve never done before,” he says. But the promise is so great that many hundreds of researchers around the world have been working on this technology. The new study looks at a very small but key detail: how to “passivate” the material’s surface, changing its properties in such a way that the perovskite no longer degrades so rapidly or loses efficiency.

“The key is identifying the chemistry of the interfaces, the place where the perovskite meets other materials,” Bulovic says, referring to the places where different materials are stacked next to perovskite in order to facilitate the flow of current through the device.

Engineers have developed methods for passivation, for example by using a solution that creates a thin passivating coating. But they’ve lacked a detailed understanding of how this process works — which is essential to make further progress in finding better coatings. The new study “addressed the ability to passivate those interfaces and elucidate the physics and science behind why this passivation works as well as it does,” Bulovic says.

The team used some of the most powerful instruments available at laboratories around the world to observe the interfaces between the perovskite layer and other materials, and how they develop, in unprecedented detail. This close examination of the passivation coating process and its effects resulted in “the clearest roadmap as of yet of what we can do to fine-tune the energy alignment at the interfaces of perovskites and neighboring materials,” and thus improve their overall performance, Bulovic says.

While the bulk of a perovskite material is in the form of a perfectly ordered crystalline lattice of atoms, this order breaks down at the surface. There may be extra atoms sticking out or vacancies where atoms are missing, and these defects cause losses in the material’s efficiency. That’s where the need for passivation comes in.

“This paper is essentially revealing a guidebook for how to tune surfaces, where a lot of these defects are, to make sure that energy is not lost at surfaces,” deQuilettes says. “It’s a really big discovery for the field,” he says. “This is the first paper that demonstrates how to systematically control and engineer surface fields in perovskites.”

The common passivation method is to bathe the surface in a solution of a salt called hexylammonium bromide, a technique developed at MIT several years ago by Jason Jungwan Yoo PhD ’20, who is a co-author of this paper, that led to multiple new world-record efficiencies. By doing that “you form a very thin layer on top of your defective surface, and that thin layer actually passivates a lot of the defects really well,” deQuilettes says. “And then the bromine, which is part of the salt, actually penetrates into the three-dimensional layer in a controllable way.” That penetration helps to prevent electrons from losing energy to defects at the surface.

These two effects, produced by a single processing step, produces the two beneficial changes simultaneously. “It’s really beautiful because usually you need to do that in two steps,” deQuilettes says.

The passivation reduces the energy loss of electrons at the surface after they have been knocked loose by sunlight. These losses reduce the overall efficiency of the conversion of sunlight to electricity, so reducing the losses boosts the net efficiency of the cells.

That could rapidly lead to improvements in the materials’ efficiency in converting sunlight to electricity, he says. The recent efficiency records for a single perovskite layer, several of them set at MIT, have ranged from about 24 to 26 percent, while the maximum theoretical efficiency that could be reached is about 30 percent, according to deQuilettes.

An increase of a few percent may not sound like much, but in the solar photovoltaic industry such improvements are highly sought after. “In the silicon photovoltaic industry, if you’re gaining half of a percent in efficiency, that’s worth hundreds of millions of dollars on the global market,” he says. A recent shift in silicon cell design, essentially adding a thin passivating layer and changing the doping profile, provides an efficiency gain of about half of a percent. As a result, “the whole industry is shifting and rapidly trying to push to get there.” The overall efficiency of silicon solar cells has only seen very small incremental improvements for the last 30 years, he says.

The record efficiencies for perovskites have mostly been set in controlled laboratory settings with small postage-stamp-size samples of the material. “Translating a record efficiency to commercial scale takes a long time,” deQuilettes says. “Another big hope is that with this understanding, people will be able to better engineer large areas to have these passivating effects.”

There are hundreds of different kinds of passivating salts and many different kinds of perovskites, so the basic understanding of the passivation process provided by this new work could help guide researchers to find even better combinations of materials, the researchers suggest. “There are so many different ways you could engineer the materials,” he says.

“I think we are on the doorstep of the first practical demonstrations of perovskites in the commercial applications,” Bulovic says. “And those first applications will be a far cry from what we’ll be able to do a few years from now.” He adds that perovskites “should not be seen as a displacement of silicon photovoltaics. It should be seen as an augmentation — yet another way to bring about more rapid deployment of solar electricity.”

“A lot of progress has been made in the last two years on finding surface treatments that improve perovskite solar cells,” says Michael McGehee, a professor of chemical engineering at the University of Colorado who was not associated with this research. “A lot of the research has been empirical with the mechanisms behind the improvements not being fully understood. This detailed study shows that treatments can not only passivate defects, but can also create a surface field that repels carriers that should be collected at the other side of the device. This understanding might help further improve the interfaces.”

The team included researchers at the Korea Research Institute of Chemical Technology, Cambridge University, the University of Washington in Seattle, and Sungkyunkwan University in Korea. The work was supported by the Tata Trust, the MIT Institute for Soldier Nanotechnologies, the U.S. Department of Energy, and the U.S. National Science Foundation.

Perovskites, a broad class of compounds with a particular kind of crystal structure, have long been seen as a promising alternative or supplement to today’s silicon or cadmium telluride solar panels. They could be far more lightweight and inexpensive, and could be coated onto virtually any substrate, including paper or flexible plastic that could be rolled up for easy transport.

In their efficiency at converting sunlight to electricity, perovskites are becoming comparable to silicon, whose manufacture still requires long, complex, and energy-intensive processes. One big remaining drawback is longevity: They tend to break down in a matter of months to years, while silicon solar panels can last more than two decades. And their efficiency over large module areas still lags behind silicon. Now, a team of researchers at MIT and several other institutions has revealed ways to optimize efficiency and better control degradation, by engineering the nanoscale structure of perovskite devices.

The study reveals new insights on how to make high-efficiency perovskite solar cells, and also provides new directions for engineers working to bring these solar cells to the commercial marketplace. The work is described today in the journal Nature Energy, in a paper by Dane deQuilettes, a recent MIT postdoc who is now co-founder and chief science officer of the MIT spinout Optigon, along with MIT professors Vladimir Bulovic and Moungi Bawendi, and 10 others at MIT and in Washington state, the U.K., and Korea.

“Ten years ago, if you had asked us what would be the ultimate solution to the rapid development of solar technologies, the answer would have been something that works as well as silicon but whose manufacturing is much simpler,” Bulovic says. “And before we knew it, the field of perovskite photovoltaics appeared. They were as efficient as silicon, and they were as easy to paint on as it is to paint on a piece of paper. The result was tremendous excitement in the field.”

Nonetheless, “there are some significant technical challenges of handling and managing this material in ways we’ve never done before,” he says. But the promise is so great that many hundreds of researchers around the world have been working on this technology. The new study looks at a very small but key detail: how to “passivate” the material’s surface, changing its properties in such a way that the perovskite no longer degrades so rapidly or loses efficiency.

“The key is identifying the chemistry of the interfaces, the place where the perovskite meets other materials,” Bulovic says, referring to the places where different materials are stacked next to perovskite in order to facilitate the flow of current through the device.

Engineers have developed methods for passivation, for example by using a solution that creates a thin passivating coating. But they’ve lacked a detailed understanding of how this process works — which is essential to make further progress in finding better coatings. The new study “addressed the ability to passivate those interfaces and elucidate the physics and science behind why this passivation works as well as it does,” Bulovic says.

The team used some of the most powerful instruments available at laboratories around the world to observe the interfaces between the perovskite layer and other materials, and how they develop, in unprecedented detail. This close examination of the passivation coating process and its effects resulted in “the clearest roadmap as of yet of what we can do to fine-tune the energy alignment at the interfaces of perovskites and neighboring materials,” and thus improve their overall performance, Bulovic says.

While the bulk of a perovskite material is in the form of a perfectly ordered crystalline lattice of atoms, this order breaks down at the surface. There may be extra atoms sticking out or vacancies where atoms are missing, and these defects cause losses in the material’s efficiency. That’s where the need for passivation comes in.

“This paper is essentially revealing a guidebook for how to tune surfaces, where a lot of these defects are, to make sure that energy is not lost at surfaces,” deQuilettes says. “It’s a really big discovery for the field,” he says. “This is the first paper that demonstrates how to systematically control and engineer surface fields in perovskites.”

The common passivation method is to bathe the surface in a solution of a salt called hexylammonium bromide, a technique developed at MIT several years ago by Jason Jungwan Yoo PhD ’20, who is a co-author of this paper, that led to multiple new world-record efficiencies. By doing that “you form a very thin layer on top of your defective surface, and that thin layer actually passivates a lot of the defects really well,” deQuilettes says. “And then the bromine, which is part of the salt, actually penetrates into the three-dimensional layer in a controllable way.” That penetration helps to prevent electrons from losing energy to defects at the surface.

These two effects, produced by a single processing step, produces the two beneficial changes simultaneously. “It’s really beautiful because usually you need to do that in two steps,” deQuilettes says.

The passivation reduces the energy loss of electrons at the surface after they have been knocked loose by sunlight. These losses reduce the overall efficiency of the conversion of sunlight to electricity, so reducing the losses boosts the net efficiency of the cells.

That could rapidly lead to improvements in the materials’ efficiency in converting sunlight to electricity, he says. The recent efficiency records for a single perovskite layer, several of them set at MIT, have ranged from about 24 to 26 percent, while the maximum theoretical efficiency that could be reached is about 30 percent, according to deQuilettes.

An increase of a few percent may not sound like much, but in the solar photovoltaic industry such improvements are highly sought after. “In the silicon photovoltaic industry, if you’re gaining half of a percent in efficiency, that’s worth hundreds of millions of dollars on the global market,” he says. A recent shift in silicon cell design, essentially adding a thin passivating layer and changing the doping profile, provides an efficiency gain of about half of a percent. As a result, “the whole industry is shifting and rapidly trying to push to get there.” The overall efficiency of silicon solar cells has only seen very small incremental improvements for the last 30 years, he says.

The record efficiencies for perovskites have mostly been set in controlled laboratory settings with small postage-stamp-size samples of the material. “Translating a record efficiency to commercial scale takes a long time,” deQuilettes says. “Another big hope is that with this understanding, people will be able to better engineer large areas to have these passivating effects.”

There are hundreds of different kinds of passivating salts and many different kinds of perovskites, so the basic understanding of the passivation process provided by this new work could help guide researchers to find even better combinations of materials, the researchers suggest. “There are so many different ways you could engineer the materials,” he says.

“I think we are on the doorstep of the first practical demonstrations of perovskites in the commercial applications,” Bulovic says. “And those first applications will be a far cry from what we’ll be able to do a few years from now.” He adds that perovskites “should not be seen as a displacement of silicon photovoltaics. It should be seen as an augmentation — yet another way to bring about more rapid deployment of solar electricity.”

“A lot of progress has been made in the last two years on finding surface treatments that improve perovskite solar cells,” says Michael McGehee, a professor of chemical engineering at the University of Colorado who was not associated with this research. “A lot of the research has been empirical with the mechanisms behind the improvements not being fully understood. This detailed study shows that treatments can not only passivate defects, but can also create a surface field that repels carriers that should be collected at the other side of the device. This understanding might help further improve the interfaces.”

The team included researchers at the Korea Research Institute of Chemical Technology, Cambridge University, the University of Washington in Seattle, and Sungkyunkwan University in Korea. The work was supported by the Tata Trust, the MIT Institute for Soldier Nanotechnologies, the U.S. Department of Energy, and the U.S. National Science Foundation.

The United States is not building enough transmission lines to connect regional power networks. The deficit is driving up electricity prices, reducing grid reliability, and hobbling renewable-energy deployment.

At the heart of the problem are utility companies that refuse to pursue interregional transmission projects, and sometimes even impede them, because new projects threaten their profits and disrupt their industry alliances. Utilities can stall transmission expansion because out-of-date laws sanction these companies’ sweeping control over transmission development.

As we increasingly electrify our homes, transportation, and factories, utility companies’ choices about transmission will have huge consequences for the nation’s economy and well-being. About 40 corporations, valued at a trillion dollars, own the vast majority of transmission lines in the United States. Their grip over the backbone of U.S. grids demands public scrutiny and accountability.

Many Lines, Stable Power

High-voltage transmission lines move large amounts of energy over long distances, linking power generation to consumption. A transmission network contains webs of connections, which create a reliable, redundant power-supply system of massive scale.

At any given time, thousands of power plants supply just enough energy to transmission networks to meet demand. The rules that orchestrate the movement of electricity through this network determine who generates power, and how much. The goal is to keep the lights on at a low cost by utilizing an efficient mix of power plants.

Building more transmission increases the capacity and connectivity of the system, allowing new power plants to connect and more power to flow between transmission networks. This is why utility companies are not embracing transmission expansion. They don’t want their power plants to face competition or their regional alliances to lose control over their networks.

Expansion can open opportunities for new power-plant and transmission developers to undercut utility companies’ profits and take control over the rules that shape the industry’s future. Utility companies are prioritizing their shareholders over the public’s need for cleaner, cheaper, and more reliable energy.

Old Alliances, Old Technology

Transmission networks in the United States, which move alternating current, were built over the last century largely by for-profit utility companies, and to a lesser extent by nonprofit utilities operated by governments and local communities. The lines tend to be concentrated around fossil-fuel reserves and population centers but are also shaped by historic utility alliances.

Where utilities agreed to trade energy, they built sufficient transmission to move power between their local service territories. As utility alliances expanded, transmission networks grew to include new members, but connections to nonallied utilities tended to be weaker.

The result of these generations-old alliances is a U.S. system fragmented into about a dozen regions with limited connectivity between them. The regions are distributed across three separate and largely isolated networks, called “interconnections”–Eastern, Western, and most of Texas.

An October 2023 report from the U.S. Department of Energy reveals the severity of the problem. Based on studies conducted by national labs and academic researchers, the DoE calculated that interregional transmission in the United States must expand as much as fivefold to maintain reliability and improve resilience to extreme weather and provide access to low-cost clean energy.

The value of linking regional networks is widely accepted globally. The European Commission in 2018 set a target for each member country to transmit across its borders at least 15 percent of the electricity produced in its territories. By the end of 2022, 23 gigawatts of cross-border connections in Europe were under construction or in advanced stages of permitting, with much more on the way.

Big Benefits

One of the main values of connecting regional networks is that it enables—and is in fact critical for—incorporating renewable energy. For instance, four proposed high-voltage lines totaling 600 kilometers along the seam of regional networks in the upper Midwest could connect at least 28 gigawatts of wind and solar. These lines have been on the drawing board for years, but utilities in the neighboring regions have not moved them forward. The cost of the project, estimated at US $1.9 billion, may seem like a major investment, but it is a fraction of what U.S. utilities spend each year rebuilding aging transmission infrastructure.

Plus, adding interregional transmission for renewables can significantly reduce costs for consumers. Such connections allow excess wind and solar power to flow to neighboring regions when weather conditions are favorable and allow the import of energy from elsewhere when renewables are less productive.

Proposed new transmission lines in the upper Midwest could connect at least 28 gigawatts of wind and solar to regional networks.Joint Targeted Interconnection Queue Study (JTIQ), MISO, SPP

Even without renewables, better integrated networks generally lower costs for consumers because they reduce the amount of generation capacity needed overall and decrease energy market prices. Interregional transmission also enhances reliability, particularly during extreme weather.

In December 2022, Winter Storm Elliott disabled power plants and pipelines from North Dakota to Georgia, leading to power outages in the South and billions of dollars in excess energy charges across the Eastern United States. Limited interregional connections staved off disaster. These links moved electricity to where it was most needed, helping to avoid the sort of catastrophe that befell Texas’s isolated electric grid the year before, when a deep freeze left millions without power for days.

Power, Profit, and Control

But from the perspective of utility companies, interregional transmission presents several drawbacks. First, building such connections opens the door for competitors who may sell lower-priced power into their region. Second, utilities make far more money constructing power plants than building transmission lines, so they are reluctant to build connections that might permanently reduce their opportunities for future generation investments.

This comparison of current interregional transfer capacity and anticipated need shows that regions will need to increase transmission significantly, assuming moderate load and high clean-energy growth.“National Transmission Needs Study,” U.S. Department of Energy

Third, major interregional transmission projects are less financially attractive to utility companies in comparison with smaller ones. For larger projects, utilities may have to compete against other developers for the opportunity to profit from construction. The utility industry sponsors third-party oversight of such projects, while smaller projects are less scrutinized by the industry. Smaller projects are easier to pull off and more profitable than the larger ones, because they need fewer construction permits, face less review by regulators and industry, and are built by utilities without competition from other developers.

Fourth, interregional lines threaten utility companies’ dominance over the nation’s power supply. In the power industry, asset ownership provides control over rules that govern energy markets and transmission service and expansion. When upstart entities build power plants and transmission lines, they may be able to dilute utility companies’ control over power-industry rules and prevent utilities from dictating decisions about transmission expansion.

Help on the Hill

Addressing the transmission shortage is on the agenda in Washington, but utility companies are lobbying against reforms. In September, Senator John Hickenlooper (D-Colo.) and Representative Scott Peters (D-Calif.) introduced the BIG WIRES Act to force utilities or competing developers to build more interregional links. In 2022, Senator Joe Manchin (D-W.Va.) proposed an approach in which transmission developers recommend projects to the DoE. If the agency deems a project to be in the national interest, federal regulators could permit the project’s construction and force utilities to pay for it.

Meanwhile, the Federal Energy Regulatory Commission (FERC) is currently reevaluating how utilities develop and operate transmission networks and may issue new rules in the coming months. In response, utilities are preparing litigation that could strip FERC of authority to impose any transmission rules at all. Their goal is to protect their profits and control, even if it comes at the consumer’s expense.

The U.S. Department of Energy is pitching in too. On 6 February, the department announced it would award $1.2 billion to support new high-voltage transmission lines, on top of the $1.3 billion it provided last fall to three interstate projects. Later this year, it plans to unveil its long-awaited national plan for a large-scale transmission build-out. But without industry support or tens of billions in additional funding from Congress to build these projects, the agency’s vision will not be realized.

Leading With Technology

New business models and technologies offer hope. Investors and entrepreneurs are developing long-distance direct-current lines, which are more efficient at moving large amounts of energy over long distances, compared with AC. These DC projects sidestep the utility-dominated transmission-expansion planning processes.

Many high-voltage DC (HVDC) transmission lines are already in operation, especially in China and Europe. In fact, DC lines are now the preferred choice in Europe’s plans to unite the continent.

The United States lacks a coordinated national planning effort to connect regional networks, but developers can make progress project by project. For example, future DC lines will connect generators in Kansas to a neighboring network in Illinois, stretch from Wyoming to California, and move wind and solar energy across the Southwest. Each of these projects will move renewable energy from where it can be generated cheaply to larger markets where power prices are higher, and in doing so they will help bolster the country’s regional transmission networks.

These pioneering projects show that utility companies in the United States don’t have to build interregional lines, but they do need to get out of the way. Transmission rules written by utilities and their industry allies can obstruct, delay, and add costs to these new projects. Streamlining federal and state permitting processes can encourage more investment, but cutting government red tape will not neutralize utility companies’ objections to interregional transmission.

U.S. regulators and Congress must press forward. Promising proposals that promote new business models and limit utility control are on the table. Our energy future is on the line.