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High-Performance Skutterudite/Half-Heusler Cascaded Thermoelectric Module Using the Transient Liquid Phase Sintering

Wenjie Li1, Gagan K Goyal1, David Stokes2

  • 1Department of Materials Science and Engineering, Pennsylvania State University, University Park, Pennsylvania16802, United States.

ACS Applied Materials & Interfaces
|January 4, 2023
PubMed
Summary

Researchers developed advanced cascaded thermoelectric (TE) devices using skutterudite (SKD) and half-Heusler (hH) materials. These devices achieve high output power for efficient solid-state waste heat recovery systems.

Keywords:
cascaded thermoelectric devicehalf-Heuslermodule fabricationpower densityskutteruditetransient liquid phase sintering

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Area of Science:

  • Materials Science
  • Energy Conversion
  • Solid-State Physics

Background:

  • Thermoelectric (TE) materials are advancing for solid-state waste heat recovery.
  • Full-scale, multistage TE devices are needed for medium to high-temperature applications.

Purpose of the Study:

  • To design and manufacture full-scale skutterudite (SKD)/half-Heusler (hH) cascaded TE devices.
  • To enhance power generation efficiency in waste heat recovery systems.

Main Methods:

  • Fabrication of 49-couple TE legs per stage using automated pick-and-place tools.
  • Development of optimized Ti/Ni/Au coating layers for metallization.
  • Utilizing Cu-Sn transient liquid phase sintering for bonding SKD and hH stages.

Main Results:

  • Achieved high output power of 38.3 W.
  • Reached a device power density of 2.8 W·cm⁻².
  • Demonstrated high strength bonding and low contact resistance.

Conclusions:

  • The developed SKD/hH cascaded TE devices show significant potential for waste heat recovery.
  • This advancement paves the way for widespread utilization of TE technology.