The objective of this work is to design a commercially viable thermoelectric generator (TEG) assembly that can be used in passenger vehicles to be able to withstand extreme environmental conditions. Since the operating temperatures of the TEGs can reach temperature levels higher than 500 °C, aluminum braze alloys offer a good high temperature solution for die attach. However, the evolution of fatigue damage in the aluminum braze must be understood in order to ensure an acceptable reliability of the TEG. In this paper, the proposed design of TEG package assembly was evaluated under extreme temperature conditions. Three-dimensional models of full scale TEG were analyzed using finite element analysis (FEA). The failures of aluminum alloy based braze (high temperature form of solder) material in the TEG application was investigated. Low cycle fatigue using direct cyclic approach was considered for the reliability analysis. Continuum damage mechanics approach was used to study the fatigue failure due to power cycling. Different TEG assembly designs were investigated and compared to determine the best possible solution for the extreme environment application.
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