NSF/DOE Thermoelectrics Partnership: Integrated Design and Manufacturing of Cost-Effective and Industrial-Scalable TEG for Vehicle Applications

1048744 Zuo知识专长：本研究项目的目标是建立和展示一种具有成本效益和工业规模的硅酸镁（Mg 2Si）和填充方钴矿热电（TE）组件的制造工艺，该工艺使用先进的热喷涂技术直接在圆柱形排气管上进行。 研究方法从非平衡材料合成和使用低成本FeSi 2的初始工艺优化的基准研究进展，然后过渡到Mg 2Si和填充方钴矿。 将使用组合的增材（热喷涂）和减材（激光切割）工艺将各种TE和支撑材料图案化到圆柱形管道上，作为大多数车辆排气组件。 并对热电器件的热电性能进行了全面表征。拟议的研究将由一个多学科团队完成，该团队由斯托尼布鲁克大学机械工程和材料科学系、高压研究中心以及布鲁克海文国家实验室凝聚态物理和材料科学系的先进能源材料组的专家组成。如果成功的话，这项研究的结果将提供一个低成本，大规模，可行的解决方案，以整合车辆TEG，以显著节省燃料，同时对能源使用和环境带来好处。它为低成本制造硅化物和填充方钴矿热电材料和器件提供了一种新的方法，以获得更高的ZT。所提出的工艺消除了传统的基于模块的TEG所需的复杂组装步骤。 材料层之间的界面粘合力本质上是强的，不需要粘合剂或机械夹紧，因此增强了热传递、界面性能和耐久性。 这项研究与教育活动相结合，这些活动将有利于研究生和本科教育的质量和多样性，以及通过我们独一无二的外展设施和计划为K-12学生提供服务。与国家实验室和行业在应用范围的不同端的互动，使开发的知识加速实施。

1048744ZuoIntellectual Merit: The objective of this research project is to establish and demonstrate a cost-effective and industrially scalable fabrication process of magnesium silicate (Mg2Si) and filled skutterudite thermoelectric (TE) components directly on cylindrical exhaust pipes using advanced thermal spray technology. The research approach progresses from non-equilibrium material synthesis and bench mark study of initial process optimization using low-cost FeSi2, and then transitioned to Mg2Si and filled skutterudites. A combined additive (thermal spray) and subtractive (laser cutting) processes will be used to pattern the various TE and support materials onto cylindrical pipes as most vehicle exhaust components. And the thermoelectric property of the TE device will be fully characterized. The proposed research will be completed by a multidisciplinary team consisting of expertise from the Departments of Mechanical Engineering and Materials Science, and the Center for High Pressure Research at Stony Brook University, and the Advanced Energy Materials group in the Condensed Matter Physics and Materials Science Department at Brookhaven National Laboratory.Broader Impact: If successful, the results of this research will provide a low-cost, large-scale, workable solution to integrate vehicle TEGs for significant fuel savings with concomitant benefits to energy usage and the environment. It creates a new approach for low-cost manufacturing of silicide and filled skutterudite thermoelectric materials and devices for higher ZT. The proposed process eliminates the complicated assembly steps required in conventional, module-based TEGs. The interface adhesion between material layers is intrinsically strong, with no adhesives or mechanical clamping required, and thus enhances heat transfer, interface performance and durability. This research is integrated with are educational activities that will benefit both quality and diversity of graduate and undergraduate education as well as K-12 students through our one-of-a-kind outreach facilities and programs. The interaction with a national lab and industry at different ends of the application spectrum enable accelerated implementation of the developed knowledge.