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In fabricating passivated emitter and rear contact (PERC) solar cells, creating small openings on the SiN x coated silicon substrate to establish metal contacts necessitates using a nanosecond pulsed green laser for ablation. However, the thermal nature of laser ablation poses a challenge. Excessive nitrogen diffusion from SiN x into the silicon substrate can compromise the electrical performance of solar cells. Therefore, this study aims to comprehensively understand how laser parameters impact the electrical properties of such solar cells. PERC solar cell precursors were initially fabricated by ablating the SiN x layer at four laser fluences, each corresponding to different regimes: solid, liquid, vapor, and phase explosion. Subsequently, various optical, chemical, and electrical characterizations were conducted on the solar cell precursors. Complete PERC solar cells were also fabricated to measure quantum efficiency (QE). In the solid regime, SiN x removal is precise, with minimal thermal damage, resulting in a nitrogen concentration of approximately 0.15%. Photoluminescence count and carrier lifetime are notably higher by 21% in the solid regime compared to the explosive regime. The QE measurement at 984 nm quantitatively assesses rear-side recombination losses. Notably, 26% of the area exhibits a 56% QE in the solid state, while this number drops to around 22% in the explosive state. This decline can be attributed to increased thermal damage in the explosive regime, which augments recombination centers and diminishes the solar cell performance. PERC solar cells ablated in the solid regime showcase lower subsurface damage, superior electrical characteristics, and higher performance than those ablated in the explosive regime. [ABSTRACT FROM AUTHOR]

Laser surface texturing uses a pulsed laser that is scanned on the surface, wherein each pulse creates a micro-crater through material ablation. A variety of textures can be generated depending on the laser parameters and the overlap of the laser spots. This work presents a computational model that can predict the topography of a textured surface produced using a nanosecond pulsed laser. The model involves a multi-physics approach that considers laser ablation with plasma effects and the melt pool's fluid dynamics to obtain the crater profile for a single pulse. The 3D surface profile created from the multi-physics model is mathematically superimposed to mimic the spatial overlapping of multiple pulses. The model predicts surface topography when a laser is scanned along a linear track with successive overlapping tracks. The experiments have confirmed that the proposed model has an accuracy greater than 90% in predicting surface roughness (Sa), as well as volume parameters such as core void volume (Vvc) and valley void volume (Vvv). It was observed that the variation of these surface characteristics is highly non-linear with the process parameters. Furthermore, the model is used to design engineered surfaces to modify friction coefficient, adhesion, and leakage probability. It is demonstrated that the surface parameters for functional requirements can be modified significantly just by varying the overlap of the laser spots in different directions. The proposed model can be used to create textured surfaces for various applications through an appropriate choice of laser parameters and scanning parameters. [ABSTRACT FROM AUTHOR]

Laser ablation of metals using nanosecond pulses occurs mainly due to vaporization. However, at high fluences, when the target is heated close to its critical temperature, phase explosion also occurs due to homogeneous nucleation. Due to a wide variation in target temperature, the material properties also show a considerable variation. In this paper, a model of laser ablation is presented that considers vaporization and phase explosion as mechanisms of material removal and also accounts for the variation in material properties up to critical temperature using some general and empirical theories. In addition, plasma shielding due to inverse bremsstrahlung and photo-ionization is considered. The model predicts accurately (within 5 %) the phase explosion threshold fluence of Al. The predictions of ablation depth by the model are in reasonable agreement with experimental measurements at low fluences. Whereas, the degree of error marginally increases at high laser fluences. [ABSTRACT FROM AUTHOR]

A number of processes such as laser ablation, laser welding, electric discharge machining, etc involve high temperatures. Most of the processes involve temperatures much higher than the target melting and normal boiling point. Such large variation in target temperature causes a significant variation in its material properties. Due to the unavailability of experimental data on material properties at elevated temperatures, usually the data at lower temperatures is often erroneously extrapolated during modelling of these processes. Therefore, this paper attempts to evaluate the variation in material properties with temperature using some general and empirical theories, along with the available experimental data for aluminum. The evaluated properties of Al using the proposed models show a significant variation with temperature. Between room temperature and near-critical temperature (0.9Tc), surface reflectivity of Al varies from more than 90% to less than 50%, absorption coefficient decreases by a factor of 7, thermal conductivity decreases by a factor of 5, density decreases by a factor of 4, specific heat and latent heat of vapourization vary by a factor between 1.5 and 2. Applying these temperature-dependent material properties for modelling laser ablation suggest that optical properties have a greater influence on the process than thermophysical properties. The numerical predictions of the phase explosion threshold in laser ablation are within 5% of the experimental values. [ABSTRACT FROM AUTHOR]