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Magnesium silicides can be used for thermoelectric energy conversion, as high values of figure of merit zT were obtained for n-type (1.4 at 500 °C) and p-type (0.55 at 350 °C) materials. This, however, needs to be complemented by low resistive and stable contacting to ensure long-term thermogenerator operation and minimize losses. In this study, we selected Cu and Ni 45 Cu 55 as contacting electrodes for their high electrical conductivity, similar coefficient of thermal expansion (CTE) and good adhesion to Mg 2 (Si,Sn). Both electrodes were joined to Mg 2 Si 0.3 Sn 0.7 pellets by hot pressing in a current-assisted press. Microstructural changes near the interface were analyzed using SEM/EDX analysis, and the specific electrical contact resistance r c was estimated using a travelling potential probe combined with local Seebeck scanning. Good contacting was observed with both electrode materials. Results show low r c with Cu, suitable for application, for both n-type and p-type silicides (< 10 µΩ•cm 2 ), with the occurrence of wide, highly conductive diffusion regions. Ni 45 Cu 55 joining also showed relatively low r c values (~ 30 µΩcm 2 ) for n-and p-type, but had a less inhomogeneous reaction layer. We also performed annealing experiments with Cu-joined samples at 450 °C for one week to investigate the evolution of the contact regions under working temperatures. r c values increased (up to ~ 100 µΩcm 2 ) for annealed n-type samples, but remained low (< 10 µΩcm 2 ) for p-type. Therefore, Cu is a good contacting solution for p-type Mg 2 (Si,Sn), and a potential one for n-type if the diffusion causing contact property degradation can be prevented.

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Thermoelectric generators are a reliable and environmentally friendly source of electrical energy. A crucial step for their development is the maximization of their efficiency. The efficiency of a TEG is inversely related to its electrical contact resistance, which it is therefore essential to minimize. In this paper, we investigate the contacting of an Al electrode on Mg2(Si,Sn) thermoelectric material and find that samples can show highly asymmetric electrical contact resistivities on both sides of a leg (e.g., 10 µΩ·cm2 and 200 µΩ·cm2). Differential contacting experiments allow one to identify the oxide layer on the Al foil as well as the dicing of the pellets into legs are identified as the main origins of this behavior. In order to avoid any oxidation of the foil, a thin layer of Zn is sputtered after etching the Al surface; this method proves itself effective in keeping the contact resistivities of both interfaces equally low (<10 µΩ·cm2) after dicing. A slight gradient is observed in the n-type leg’s Seebeck coefficient after the contacting with the Zn-coated electrode and the role of Zn in this change is confirmed by comparing the experimental results to hybrid-density functional calculations of Zn point defects.

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