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

1048744 Zuo智能优点：该研究项目的目标是利用先进的热喷涂技术，直接在圆柱形排气管上建立和演示一种具有成本效益和工业可扩展的硅酸镁(Mg2Si)和填充Skutterudite热电(TE)组件的制造工艺。研究方法从非平衡材料合成和利用低成本FeSi2进行初始工艺优化的试验台研究进展，然后过渡到Mg2Si和填充方锰矿。加法(热喷涂)和减法(激光切割)相结合的工艺将被用于将各种TE和支撑材料作为大多数汽车排气部件的圆柱形管道。并对TE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，该团队由来自机械工程和材料科学系、石溪大学高压研究中心和布鲁克海文国家实验室凝聚态物理和材料科学系的高级能源材料小组的专业知识组成。广泛影响：如果成功，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，将车辆测试整合在一起，显著节省燃料，并伴随着能源使用和环境的好处。这为低成本制造硅化物和填充方钛矿的热电材料和器件创造了一条新的途径。所提出的工艺消除了传统的基于模块的测试中所需的复杂的组装步骤。材料层之间的界面粘附性本质上很强，不需要粘合剂或机械夹持，从而增强了传热、界面性能和耐用性。这项研究与教育活动相结合，通过我们独一无二的外展设施和计划，使研究生和本科教育的质量和多样性以及K-12学生受益。在应用范围的不同端与国家实验室和行业的互动使所开发的知识能够加速实施。

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.