Radioisotope thermoelectric generator (RTG) is one of ideal power sources for deep space exploration due to the long service life and high stability. To further extend service life and improve electrical output, this study is first to simultaneously optimize electrical output and mechanical stability induced by thermal stress of the two-stage RTG using non-dominated sorting genetic algorithm-II. Skutterudite and bismuth telluride are used as the thermoelectric materials in hot-stage and cold-stage thermoelectric generators, respectively. The maximum von Mises stress of the skutterudite-stage (VonSKD) and bismuth telluride-stage (VonBT) thermoelectric generator and the conversion efficiency of the two-stage RTG (ηtwo) are set to the three objectives, and twelve geometrical parameters of two-stage RTG are used as variables. Electrical output and mechanical stability are simulated with COMSOL 6.0 Multiphysics software based on the finite element method. Results show that the ranges of ηtwo, VonSKD, and VonBT in the Pareto front are 4.81–7.57 %, 112.2–228.46 and 19.24–87.33 MPa, respectively, when the temperature difference is 300 K. TOPSIS decision-making method is used to select the specific optimal solution on the Pareto front according to the weight of the different objectives. Comparisons between tri- and bi-objective as well as single-stage optimization are also carried. Results show that there are strong influences among these three objectives. The performance of one objective would improve at the expense of the performance of the remaining objectives decrease if a larger weight was given. The VonSKD has the greatest importance among the three objectives, followed by ηtwo, and the smallest is VonBT. Skutterudite-stage thermoelectric generator should be particularly considered in the design of two-stage RTGs. The two-stage RTGs with different weight factors exhibit different electrical performances due to different geometrical parameters. This research can provide references for two-stage thermoelectric generators in more scenarios to improve electrical performances and extend service life.
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