Thermal and Interfacial Stability of PPS-Fabricated Segmented Skutterudite Legs for Thermoelectric Applications

The development of thermoelectric modules based on skutterudite materials requires stable, low-resistance interfaces between segments operating at different temperature ranges. This study investigates the microstructure, thermoelectric performance, and thermal stability of the following two joints: In_0.4Co₄Sb₁₂/Co₄Sb_10.8Te_0.6Se_0.6 (n-type) and CeFe₃Co_0.5Ni_0.5Sb₁₂/In_0.25Co₃FeSb₁₂ (p-type), fabricated by pulse plasma sintering (PPS). Scanning electron microscopy (SEM) and energy-dispersive spectroscopy (EDS) analyses confirmed the formation of well-bonded interfaces without pores or cracks. Aging at 773 K for 168 h did not result in morphological or chemical degradation, and phase composition remained unchanged according to X-ray diffraction (XRD). Surface Seebeck coefficient mapping and contact resistance measurements showed negligible changes after annealing, confirming electrical stability. To provide context for potential applications, theoretical energy conversion efficiencies were estimated based on measured thermoelectric properties, yielding 13.2% and 10.1% for the n- and p-type segmented legs, respectively. Additionally, measured coefficients of thermal expansion (CTE) indicated low mismatch between jointed materials, supporting good mechanical compatibility. The results demonstrate that the selected material combinations are thermally, chemically, and electrically stable and can be effectively used in segmented thermoelectric legs for intermediate-temperature applications.