Manufacturing an economically viable,
efficient commercial thermoelectric
(TE) module is essential for power generation and refrigeration. However,
mediocre TE properties, lack of good mechanical stability of the material,
and significant difficulties involved in the manufacturing of large-scale
powder as well as bulk samples hinder the potential applications of
the modules. Herein, an economically feasible single-step water atomization
(WA) is employed to synthesize BST powder (2 kg) by Cu doping within
a short time and consolidated into large-scale bulk samples (500 g)
for the first time with a diameter of 50 mm and a thickness of about
40 mm using spark plasma sintering (SPS). The incorporation of Cu
into BST greatly boosts the carrier concentration, leading to a significant
increase in electrical conductivity, and inhibits the bipolar thermal
conductivity by 73%. Synchronously, the lattice contribution (κL) is greatly reduced by the effective scattering of phonons
by comprising fine-grain boundaries and point defects. Therefore,
the peak ZT is shifted to the mid-temperature range
and obtained a maximum of ∼1.31 at 425 K and a ZT
ave of 1.24 from 300 to 500 K for the BSTCu0.05 sample, which are considerably greater than those of the bare BST
sample. Moreover, the maximum compressive mechanical strength of large-size
samples manufactured by the WA-SPS process is measured as 102 MPa,
which is significantly higher than commercial zone melting samples.
The thermoelectric module assembled with WA-SPS-synthesized BSTCu0.05 and commercial n-type BTS material manifests an outstanding
cooling performance (−19.4 °C), and a maximum output power
of 6.91 W is generated at ΔT ∼ 200 K.
These results prove that the BSTCu
x
samples
are eminently suitable for the fabrication of industrial thermoelectric
modules.