Diamond wire sawing is expected to capture 90% market share for photovoltaic monocrystalline silicon wafering by 2020. An analysis of the cost of ownership reveals that the diamond wire consumption is the biggest cost driver. In this research project, the goal is to understand why and how the diamond wire breaks and wears in order to improve its durability.
Sponsored by: U.S. Department of Energy (SunShot PVMI)
New vs. Used Diamond Wire
![Maginified image of new diamond wire that cuts photovoltaic silicon ingot](https://energyresearch.ucf.edu/wp-content/uploads/2017/01/DW-new-300x300.jpg)
![Magnified view of old diamond wire](https://energyresearch.ucf.edu/wp-content/uploads/2017/01/DW-old-300x300.jpg)
Failure Modes
![Macro view of diamond wire with a tensile failure.](https://energyresearch.ucf.edu/wp-content/uploads/2017/01/DW-tensile-failure-01-300x300.jpg)
![Macro view of diamond wire with a twist failure.](https://energyresearch.ucf.edu/wp-content/uploads/2017/01/DW-twist-failure-01-300x300.jpg)
Wear Mechanisms
![Macro view of diamond wire with a broken diamond.](https://energyresearch.ucf.edu/wp-content/uploads/2017/01/wear-mechanisms-01-300x300.jpg)
![Macro view of diamond wire with dislodged diamond wear.](https://energyresearch.ucf.edu/wp-content/uploads/2017/01/wear-mechanisms-02-300x300.jpg)
![Macro view of diamond wire with a damaged Ni coating.](https://energyresearch.ucf.edu/wp-content/uploads/2017/01/wear-mechanisms-03-300x300.jpg)
![Macro view of diamond wire with scratch.](https://energyresearch.ucf.edu/wp-content/uploads/2017/01/wear-mechanisms-04-300x300.jpg)
Wear Rates
![Graph showing variation in wear rates among commercially available diamond wires.](https://energyresearch.ucf.edu/wp-content/uploads/2017/01/Graph-DW-wear-cz-ingot-1024x595.jpg)
![Graph of diamond wire wear as a function of CZ ingot properties.](https://energyresearch.ucf.edu/wp-content/uploads/2017/01/Graph-DWwearVSIngot-1024x618.jpg)