Melt
spinning has proven effective in maintaining chemical homogeneity
and introducing multiscale microstructures that can reduce the lattice
thermal conductivity and consequently enhance the thermoelectric performance
of consolidated bulk materials. In this work, p-type Bi0.52Sb1.48Te3 bulk alloys are fabricated by melt
spinning (MS) followed by subsequent plasma activated sintering (PAS).
The influence of different MS atmospheres (air, Ar, N2,
and He) on the morphologies of MS ribbons and the thermoelectric properties
of MS-PAS bulk materials has been investigated systematically. Because
of the relatively high thermal conductivity, a He atmosphere expedites
the heat dissipation in the MS process and results in severe sublimation
of tellurium and thus inferior thermoelectric performance. In contrast,
an Ar atmosphere can essentially prevent heat loss of the fusant and
suppress the sublimation of tellurium. Consequently, the corresponding
Bi0.52Sb1.48Te3 sample (MS in Ar
atmosphere) presents the highest peak ZT and average ZT values of
1.09 (at 340 K) and 0.81 (in 300–500 K), respectively. The
average ZT of the sample prepared using an Ar atmosphere is almost
three times the one prepared using a He atmosphere. This reflects
the importance of using the appropriate atmosphere during the melt-spinning
process. This result, which indicates that melt spinning in an Ar
atmosphere is preferable to avoid heat loss, can also be extended
to other materials.