Addressing fabrication challenges in perovskite-silicon tandem solar cells with advanced simulation techniques

Materials for Renewable and Sustainable Energy https://doi.org/10.1007/s40243-024-00284-5 (2025) 14:18 ORIGINAL PAPER Addressing fabrication challenges in perovskite-silicon tandem solar cells with advanced simulation techniques Raman Kumar1,2 · Prakash Kanjariya3 · A. Abu-Jrai4 · Nagaraj Patil5 · Mohd Shukri Ab Yajid6 · Jatinder Kaur7 · Rahul Singh8 · P. Vijaya Kumar9 · Sanjeev Kumar Shah10 · Mohammad Iqbal Khairandish11 Received: 17 October 2024 / Accepted: 28 November 2024 © The Author(s) 2024 Abstract In the pursuit of higher conversion efficiency, the PV industry has turned its focus towards perovskite-silicon tandem solar cells, which currently represent the peak of innovation. To surpass the efficiency limits of traditional single-junction cells, researchers are exploring the potential of these tandem solar cells by integrating the merits of perovskite and silicon. However, integrating these cells brings different challenges, such as deposition methods and material misalignments. Thus, in this work, we are using advanced simulation techniques, including Silvaco ATLAS’s Victory Process and Device Simulator to imitate the actual manufacturing processes. Primarily this research work focuses on three scenarios: shunting, planarization and conformal deposition to emulate the experimental conditions. The obtained results show the potential and effectiveness of process simulations in accurately predicting and improving the PV performance of the tandem solar cell. Two different perovskite-silicon tandem solar cells are designed using process simulations which showed a conversion efficiency of 27.51% and 29.08% respectively. This work highlights the importance of using simulation tools for the further development of tandem solar cell technology. Detailed process and device simulations reported in this work may pave the way in the fabrication of optimised perovskite/silicon tandem solar cell. Keywords Perovskite · Silicon · Tandem · Simulation · Photovoltaics · Efficiency · Deposition · Shunting · Fabrication · Optimization Mohammad Iqbal Khairandish 6 Management and Science University, Shah Alam, Selangor, Malaysia 7 Department of Electronics and Communication Engineering, Division of Research & Innovation, Chandigarh Engineering College, Chandigarh Group of Colleges Jhanjeri, Mohali, Punjab 140307, India 1 University School of Mechanical Engineering, Rayat Bahra University, Kharar, Punjab 140103, India 2 Faculty of Engineering, Sohar University, PO Box 44, Sohar PCI 311, Oman 8 3 Department of Physics, Faculty of Science, Marwadi University Research Center, Marwadi University, Rajkot, Gujarat 360003, India Department of Mechanical & Aerospace Engineering, NIMS Institute of Engineering & Technology, NIMS University Rajasthan, Jaipur, India 9 4 College of Engineering, Applied Science University, Eker, Kingdom of Bahrain Department of Mechanical Engineering, Raghu Engineering College, Visakhapatnam, Andhra Pradesh 531162, India 10 5 Department of Mechanical Engineering, School of Engineering and Technology, JAIN (Deemed to be University), Bangalore, Karnataka, India Department of Electronics & Communication Engineering, Uttaranchal Institute of Technology, Uttaranchal University, Dehradun, Uttarakhand 248007, India 11 Department of Civil Engineering, Jami University, Herat, Afghanistan 13 18 Page 2 of 8 Introduction Continuous advancements in PV technologies have facilitated new design of solar cells for improved conversion efficiency and performance. However, the improvements in silicon PV technology have pushes their efficiencies higher, but the bottleneck to surpass the S-Q limit is not be possible with this technology [1–3]. Thus, the new technologies such as tandem designs, PERC solar cell, graded solar cell and many other PV technologies are explored by various researchers [4–9]. Among all these technologies tandem solar cells (TSC) offers remarkable benchmarks in photovoltaics. Precisely, the perovskite/silicon TSC stand out most interesting option due to their ability to merge the strengths of perovskite’s superior light absorption with silicon’s wellestablished stability [8–12]. The integration of perovskite and silicon harness a wide AM1.5G spectrum, leading to offering higher power conversion efficiency than traditional solar cells. This combination of perovskite and silicon cells holds promise for surpassing the conversion efficiency limitations of single-junction cells. Thereby marking the perovskite/silicon TSC technology as center of attraction for the researchers. Continuous efforts of researchers in terms of architecture engineering, interface engineering and also the refinement of fabrication techniques has resulted in notable progress in perovskite/silicon TSC [9, 10]. These improvements have generated significant interest in TSCs as an efficient alternative to conventional PV technology, addressing key performance barriers faced by single-layer devices. Despite these advances, combining perovskite/ silicon cells poses specific technical challenges depicted in Fig. 1. The major challenge while employing the high bandgap top cell perovskite layer is faced during deposition Materials for Renewable and Sustainable Energy (2025) 14:18 via such as spin coating, co-evaporation, and slot-die or blade coating, that demands for careful consideration. There are further challenges as well such as material misalignment and the complexities associated with applying the top layer on textured silicon surfaces, that demands innovative approaches to achieve optimal amalgamation and functionality [12–15]. For efficient development of perovskite/silicon TSCs advanced process simulation tools are essential in addressing the fabrication challenges. These process simulation tools provide the opportunity to accurately model complex semiconductor devices that help researchers to replicate real-world scenarios. Also, by simulating and analyzing intricate fabrication processes, these advanced process simulation helps in optimizing device performance [20, 21]. For the continuous advancements of tandem PV technology, the process simulation tool offers valuable insights. One such process simulation tool is the Victory Process simulation module of Silvaco ATLAS [22]. This Victory process tool accurately models the fabrication processes of semiconductor devices, making it worthy for the development of perovskite/silicon TSC. This tool has the ability to emulate the actual detailed fabrication steps, and thus it helps in enhancing the understanding of TSC, subsequently aiding in their optimization. After the Introduction section, the subsequent sections outline the methodology used in process simulation using the Victory module (Process and device simulation methodology), present the findings, and discuss the broader implications of this research for the future progress and optimization of perovskite/silicon TSCs (Results and discussions (device str (...truncated)