Research » Solar Technologies Research » Diamond Wire Failure Modes and Wear Mechanisms

Diamond Wire Failure Modes and Wear Mechanisms

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
New Diamond Wire
Magnified view of old diamond wire
Old Diamond Wire

 

 

 

 

 

 

 

 

 

Failure Modes

Macro view of diamond wire with a tensile failure.
Tensile Failure
Macro view of diamond wire with a twist failure.
Twist Failure

 

 

 

 

 

 

 

 

 

Wear Mechanisms

Macro view of diamond wire with a broken diamond.
Broken Diamond
Macro view of diamond wire with dislodged diamond wear.
Dislodged Diamond
Macro view of diamond wire with a damaged Ni coating.
Damaged Ni Coating
Macro view of diamond wire with scratch.
Scratched

 

 

 Wear Rates

Graph showing variation in wear rates among commercially available diamond wires.
Variation in wear rates among commercially available diamond wires
Graph of diamond wire wear as a function of CZ ingot properties.
Diamond wire wear as a function of CZ ingot properties

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