A Low-Cost Production Method of FeSi2 Power Generation Thermoelectric Modules

Abstract

A method is proposed to reduce the production cost of power generation thermoelectric modules. FeSi2 is employed as the thermoelectric material because of its low cost, low environmental load, and oxidation resistance. The raw materials were prepared in the composition of Fe0.96Si2.1Co0.04 for n-type and Fe0.92Si2.1Mn0.08 for p-type, which were added with 0.5 wt.% Cu as the starting materials. They were sintered without pressure at 1446 K to be formed into elements. The Seebeck coefficient and resistivity at room temperature were determined to be −182 μV/K and 0.13 mΩm for n-type, and 338 μV/K and 1.13 mΩm for p-type, respectively. The brazing conditions of the direct joining between the element and the solder were examined. Pastes of BNi-6, BNi-7 or TB-608T were tried as the solder. TB-608T was useable for metallizing of insulation substrates and joining of thermoelectric elements in order to manufacture thermoelectric modules. The joining strength was determined to be 50 MPa between the alumina plate and the elements. No mechanical failure was observed in the modules after repetition of 10 or more exposures to a heat source of 670 K. No change was found in the internal resistance. The present production method will provide modules with high durability and low production cost, which will enable high-power multi-stage cascade modules at a reasonable cost.