Silicon has been one among a few key technologically important materials especially in our modern world. Silicon, especially in its current most useful forms (thin layers), is a brittle material by nature. Thin silicon cells crack easily during manufacturing assembly. Every crack is a defect in any PV manufacturing lines, and if let to grow/propagate it will lead to reliability and quality issues with time. Nevertheless, the global silicon solar PV industry is aggressively reducing the cost of solar PV systems through cutting down the thickness of silicon solar cells. Cell cracks immediately lower PV module efficiency and can lead to premature aging of the entire module. The “Crack Catcher AI” was our research joint collaboration's entry in the Department of Energy (DOE)'s American-Made Solar Innovation competition in 2022 (Round 6) which later was selected as the national semifinalists and won an award announced by DOE in December 2022. It uses smart stress sensing and smart fracture prediction approaches utilizing fundamental fracture mechanics and big data analytics to reduce crack defects and enhance long-term durability/reliability of PV products/devices. Smart Stress Sensing uses a novel laser-based curvature methodology for fast in-line stress metrology in manufacturing lines. Smart Fracture Prediction uses Artificial Intelligence (AI) for defect control metrology and yield enhancement in PV production lines. It is based on monocrystalline silicon used in solar PV industries, but all scientific principles utilized and technological innovations developed in this article would be applicable as well for single crystal silicon semiconductor wafers.
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