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由于能够实现热能和电能的直接转换，中高温区热电器件在深空探测、工业余废热回收等领域具有巨大的应用潜力。半赫斯勒合金由于优异的机械性能、热稳定性和良好的热电表现，成为中高温区热电器件制作的有潜力的候选材料。然而与半赫斯勒热电材料的研究相比，相应的器件研究还远远滞后，制约了其大规模的工业应用。本研究首先制备了高性能P型和N型半赫斯勒合金，采用自主设计的石墨模具成功钎焊组装了单对半赫斯勒热电器件。之后采用有限元分析方法对单对器件进行三维仿真建模，同时建立一维数值模型进行对比。除此之外，开发了一套自主集成的综合测试系统，系统地表征了单对器件的输出功率、转换效率等关键热电性能。两种模型仿真预测结果与实验测量数据高度一致，在工作温差达到538K时，最大输出功率和最大转换效率分别为0.28W和7.34%，能够与目前报道的器件最佳性能相媲美。本研究结果可以为半赫斯勒热电器件的实际制作、仿真建模和表征测量提供参考。Due to the ability to directly convert thermal energy into electrical energy, thermoelectric devices operating in the medium-to-high temperature range hold significant potential for applications such as deep space exploration and industrial waste heat recovery. Among candidate materials, half-Heusler alloys have emerged as promising options for device fabrication in this temperature range, owing to their excellent mechanical properties, thermal stability, and favorable thermoelectric performance. However, research on half-Heusler-based thermoelectric devices remains far behind that on the materials, limiting their large-scale industrial application. In this study, high-performance p-type Hf0.5Zr0.5CoSb0.8Sn0.2 and n-type Hf0.75Zr0.25NiSn0.99Sb0.01 half-Heusler alloys were firstly synthesized. Then the single-pair thermoelectric module was successfully brazing assembled by the self-designed graphite mold. After that, 3D finite element modeling and 1D numerical modeling were conducted to simulate the module behavior, both showing strong agreement with experimental measurements, thereby validating the accuracy of the simulation models. Using the established simulation models, the influence of geometric parameters on module performance was investigated. It was found that optimizing the leg height and cross-sectional area ratio is critical for achieving maximum conversion efficiency. Additionally, a self-integrated comprehensive testing system (Model: TE-X-MS) was developed to systematically characterize key thermoelectric properties, including output power and conversion efficiency. The fabricated device achieved a maximum output power of 0.28 W and a peak conversion efficiency of 7.34% under a temperature difference of 538K, which is comparable to the best-performing devices reported to date. These results provide valuable reference into the fabrication, modeling, and characterization of half-Heusler thermoelectric devices for practical applications.
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Keywords:
- Half-Heusler alloy /
- Thermoelectric generator /
- Finite element simulation /
- numerical simulation
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