We report a melt spinning technique followed by a quick spark plasma sintering procedure to fabricate high-performance p-type Bi0.52Sb1.48Te3 bulk material with unique microstructures. The microstructures consist of nanocrystalline domains embedded in amorphous matrix and 5–15 nm nanocrystals with coherent grain boundary. The significantly reduced thermal conductivity leads to a state-of-the-art dimensionless figure of merit ZT∼1.56 at 300 K, more than 50% improvement of that of the commercial Bi2Te3 ingot materials.

Herein, we report the synthesis of multiscale nanostructured p-type (Bi,Sb)(2)Te(3) bulk materials by melt-spinning single elements of Bi, Sb, and Te followed by a spark plasma sintering process. The samples that were most optimized with the resulting composition (Bi(0.48)Sb(1.52)Te(3)) and specific nanostructures showed an increase of approximately 50% or more in the figure of merit, ZT, over that of the commercial bulk material between 280 and 475 K, making it suitable for commercial applications related to both power generation and refrigeration. The results of high-resolution electron microscopy and small angle and inelastic neutron scattering along with corresponding thermoelectric property measurements corroborate that the 10-20 nm nanocrystalline domains with coherent boundaries are the key constituent that accounts for the resulting exceptionally low lattice thermal conductivity and significant improvement of ZT.

High performance Bi2Te3 bulk materials with layered nanostructure have been prepared by combining melt spinning technique with spark plasma sintering, and their thermoelectric transport properties are investigated. The electrical conductivity increases greatly and the lattice thermal conductivity decreases significantly with the increase of the roller’s linear speed. These lead to a great improvement in the thermoelectric figure of merit (ZT). The maximum ZT value of 1.35 is obtained at 300K for the sample which is prepared by melt spinning with roller linear speed of 40m∕s. Compared with the zone melting sample, it increases by 73% at the same temperature.

Half-Heusler (HH) alloys have attracted considerable interest as promising thermoelectric (TE) materials in the temperature range around 700 K and above, which is close to the temperature range of most industrial waste heat sources. The past few years have seen nanostructuing play an important role in significantly enhancing the TE performance of several HH alloys. In this article, we briefly review the recent progress and advances in these HH nanocomposites. We begin by presenting the structure of HH alloys and the different strategies that have been utilized for improving the TE properties of HH alloys. Next, we review the details of HH nanocomposites as obtained by different techniques. Finally, the review closes by highlighting several promising strategies for further research directions in these very promising TE materials.

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We report a detailed description of an innovative route of a melt spinning (MS) technique combined with a subsequent spark plasma sintering process in order to obtain high performance p-type Bi0.52Sb1.48Te3 bulk material, which possesses a unique low-dimensional structure. The unique structure consists of an amorphous structure, 5–15 nm fine nanocrystalline regions, and coherent interfaces between the resulting nanocrystalline regions. Measurements of the thermopower, electrical conductivity, and thermal conductivity have been performed over a range of temperature of 300–400 K. We found that MS technique can give us considerable control over the resulting nanostructure with good thermal stability during the temperature range of 300–400 K and this unique structure can effectively adjust the transport of phonons and electrons, in a manner such that it is beneficial to the overall thermoelectric performance of the material, primarily a reduction in the lattice thermal conductivity. Subsequently, this results in a maximum figure of merit ZT value of 1.56 at 300 K for p-type Bi0.52Sb1.48Te3 bulk material. This ZT value is over a 50% improvement of that of the state of the art commercial Bi2Te3 materials. We also report results of thermal cycling of this material for over one hundred cycles between 300–400 K. Our work offers an innovative route for developing high performance bismuth telluride based alloys and devices, which have even broader prospects for commercial applications. This technique may also be applicable to other thermoelectric materials.

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