Hostname: page-component-74656f9884-j7cmm Total loading time: 0 Render date: 2026-11-06T09:54:22.197Z Has data issue: false hasContentIssue false

Development of a Bi2Te3-based thermoelectric generator with high-aspect ratio, free-standing legs

Published online by Cambridge University Press:  13 February 2012

D.E. Wesolowski*
Affiliation:
Sandia National Laboratories, Albuquerque, New Mexico 87185
R.S. Goeke
Affiliation:
Sandia National Laboratories, Albuquerque, New Mexico 87185
A.M. Morales
Affiliation:
Sandia National Laboratories, Albuquerque, New Mexico 87185
S.H. Goods
Affiliation:
Sandia National Laboratories, Albuquerque, New Mexico 87185
P.A. Sharma
Affiliation:
Sandia National Laboratories, Albuquerque, New Mexico 87185
M.P. Saavedra
Affiliation:
Sandia National Laboratories, Albuquerque, New Mexico 87185
K.R. Reyes-Gil
Affiliation:
Sandia National Laboratories, Albuquerque, New Mexico 87185
W.C.G. Neel
Affiliation:
Sandia National Laboratories, Albuquerque, New Mexico 87185
N.Y.C. Yang
Affiliation:
Sandia National Laboratories, Albuquerque, New Mexico 87185
C.A. Apblett
Affiliation:
Sandia National Laboratories, Albuquerque, New Mexico 87185
*
a)Address all correspondence to this author. e-mail: dewesol@sandia.gov

Abstract

A bismuth telluride alloy-based thermoelectric generator with high-aspect ratio, free-standing legs was fabricated. Such legs are desirable for efficient generator performance from low-grade heat sources but are difficult to assemble because they are fragile and difficult to handle and position. Plunge and wire electro-discharge machining (EDM) were used to produce 150 μm × 300 μm legs, approximately 6-mm long, with high fidelity. Removal of recast material from EDM was necessary for good adhesion of metallization, but sputter etching was found to deteriorate the mechanical strength of the contacts. A wet chemical cleaning process was developed instead that resulted in good adhesion under test conditions. Au was preferred for designs where interconnects could be patterned directly on the module. Module figure of merit (ZT) was 0.72, close to the 0.85 value expected from bulk material property measurements. Impedance spectroscopy and the Harman technique were shown to significantly underestimate module ZT in the present test configuration. Shear and fatigue testing were performed on arrays of high-aspect ratio legs. Legs survived over 104 cycles of shear loading at 90% of the load to failure.

Information

Type
Articles
Copyright
Copyright © Materials Research Society 2012
Figure 0

FIG. 1. P- and N-type Bi2Te3 wafers. (a) Wafer as-cut by wire electro-discharge machining (EDM) from Bi2Te3 ingot and after patterning with sinker EDM. (b) Grills with gold shunts placed in alumina carrier plates, ready for stacking.

Figure 1

FIG. 2. Assembled module. (a) After facing cut and interconnect deposition. (b) Fully assembled.

Figure 2

FIG. 3. Sputtered Au films on bismuth telluride after heat treatment under vacuum.

Figure 3

FIG. 4. Figure of merit (ZT) measurements on P- and N-type material before and after heating, with and without gold. No significant differences are observed.

Figure 4

FIG. 5. Circuit equivalent for thermoelectric module (TEM) tests (replace with model including series inductor).

Figure 5

FIG. 6. Transient TEM evaluation (a) Nyquist plot of TEM impedance spectrum. The circle indicates the fit to a capacitive circuit element. (b) Potential versus time plot for Harman technique. Both techniques indicate a module ZT of approximately 0.64.

Figure 6

FIG. 7. Seebeck coefficient calculated from equilibrium measurements.

Figure 7

FIG. 8. Fatigue testing of 12 N-type leg arrays. (a) Applied load by cycle number. (b) Load–displacement curve as at end of cycle tests.