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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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