Environmental Corrosion and Long-term Degradation of Crystalline Silicon Solar Cells: Mechanisms, Climate Effects and Mitigation Strategies

Abstract

Crystalline silicon solar cells form the backbone of modern photovoltaic technology, yet their long-term performance is increasingly threatened by environmental degradation. This review examines the mechanisms of corrosion and chemical deterioration in crystalline silicon absorbers, focusing specifically on the silicon layer rather than broader module-level failures. The article integrates both laboratory-based accelerated testing and long-term field studies conducted in humid, coastal, and desert climates. Key stressors such as moisture ingress, ionic contamination, ultraviolet radiation, and thermal cycling were found to accelerate surface oxidation, dopant migration, shunting pathways, and microstructural damage. Microcracks and encapsulant defects further intensified corrosion by promoting localized degradation. Field evidence indicates that degradation patterns vary by climate, with salt-induced corrosion being dominant in coastal environments, while thermal cycling and dust effects are more critical in desert regions. The review also evaluates emerging mitigation strategies, including advanced passivation, corrosion-resistant metallization, and improved encapsulants, with emphasis on their relevance across different climates. By linking corrosion mechanisms with climate-specific impacts, this article provides a framework for predicting absorber-level degradation, guiding design improvements, and informing durability assessments for next-generation silicon photovoltaics.