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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.
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.
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.
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