| Abstract Scope |
Thermoelectric generators (TEGs), based on the Seebeck effect, are solid-state devices that convert heat into electricity and offer great promise for waste heat recovery. However, their widespread adoption is hindered by low conversion efficiency, limited high-temperature fabrication techniques, and inadequate long-term reliability. Achieving efficient and reliable power generation requires not only high-performance thermoelectric materials with a high figure of merit (zT), but also robust module fabrication processes. In this presentation, we discuss key considerations and techniques for fabricating reliable, high-efficiency TEG modules. We demonstrate a process that achieves low thermal and electrical contact resistance at temperatures up to 600 °C, using bismuth telluride and half-Heusler materials. A high-temperature brazing approach enables direct bonding of thermoelectric legs to copper electrodes, eliminating the need for metallization in half-Heusler modules. With optimized fabrication and materials integration, we have achieved conversion efficiencies up to 15%, highlighting the potential of TEGs for efficient waste heat recovery. |