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The NASA enhanced MMRTG (eMMRTG) project seeks to enhance the performance of the Multi-Mission Radioisotope Thermoelectric Generator by exchanging the heritage thermoelectric couple materials and design with that of more efficient skutterudite (SKD)-based thermoelectric (TE) couples. Both at the Jet Propulsion Lab—where the SKD materials were developed—and at Teledyne Energy Systems, Inc.—where the technology is being matured and optimized for fabrication under the Skutterudite Technology Maturation (SKD Tech Mat) Project—many SKD material batches have been produced. A strong correlation has been observed between the TE performance of the materials and the particular lot numbers (same producer and supplier) of various raw materials used to produce the SKD materials. An analysis of the differences between lots, their effects on performance, and the current plan to mitigate the risk posed by these results is discussed.

Twenty-six (Pb0.95Sn0.05Te)0.92(PbS)0.08–0.055% PbI2–SiC nanoparticle (SiCnp) composite thermoelectric specimens were either hot pressed or pulsed electric current sintered (PECS). Bloating (a thermally induced increase in porosity, P, for as-densified specimens) was observed during annealing at temperatures >603 K for hot-pressed specimens and PECS-processed specimens from wet milled powders, but in contrast seven out of seven specimens densified by PECS from dry milled powders showed no observable bloating following annealing at temperatures up to 936 K. In this study, bloating in the specimens was accessed via thermal annealing induced changes in (i) porosity measured by scanning electron microscopy on fractured specimen surfaces, (ii) specimen volume and (iii) elastic moduli. The moduli were measured by resonant ultrasound spectroscopy. SiCnp additions (1–3.5 vol.%) changed the fracture mode from intergranular to transgranular, inhibited grain growth, and limited bloating in the wet milled PECS specim...

Lead-antimony-silver-tellurium (LAST) thermoelectric materials are candidates for waste-heat recovery applications. However, rapid heating and cooling (thermal shock) imposes thermomechanical stresses that can cause microcracking. Waste-heat recovery applications involve thermal fatigue, in which a series of hundreds or thousands of individual thermal shock events can lead to accumulation of microcrack damage in brittle thermoelectrics such as LAST. Microcracking in turn leads to a decrease in transport properties, such as electrical conductivity and thermal conductivity, and mechanical properties, including elastic modulus and strength. Thus, microcracking can affect both thermoelectric performance and mechanical integrity. In this study, LAST specimens were rapidly cooled (quenched) into a fluid (water or silicone oil) in order to compare the results with the vast majority of thermal shock studies of brittle materials that are quenched in a similar manner. Decreases in elastic modulus, E, with accumulating microcrack damage were measured using resonant ultrasound spectroscopy (RUS). The evolution of thermal fatigue damage observed in this study is also described well by an equation that successfully describes thermal fatigue damage in a variety of brittle materials.

During waste heat recovery applications, thermoelectric (TE) materials experience thermal gradients and thermal transients, which produce stresses that scale with the TE material's coefficient of thermal expansion (CTE). Thus, the temperature-dependent CTE is an important parameter for the design of mechanically robust TE generators. For three skutterudite thermoelectric compositions, n-type Co0.95Pd0.05Te0.05Sb3 (with and without 0.1 at. % cerium doping) and p-type Ce0.9Fe3.5Co0.5Sb12, the CTE was measured using two methods, i.e. X-ray diffraction on powder and bulk specimens and dilatometry on bulk specimens. Each bulk specimen was hot pressed using powders milled from cast ingots. Between 300 K and 600 K, the mean CTE values were 9.8–10.3 × 10−6 K−1 for the non-cerium-doped n-type, 11.6 × 10−6 K−1 for the 0.1 at. % cerium-doped n-type and from 12.7 to 13.3 × 10−6 K−1 for the p-type. In the literature, similar CTE values are reported for other Sb-based skutterudites. For temperatures >600 K, an unrecove...

Effective models of the mechanical behavior of thermoelectric materials under device conditions require knowledge of temperature-dependent elastic properties. Between room temperature and 600 K, resonant ultrasound spectroscopy measurements of three skutterudite thermoelectric materials, i.e. n-type Co0.95Pd0.05Te0.05Sb3 (both with and without 0.1 at.% cerium dopant) and p-type Ce0.9Fe3.5Co0.5Sb12, showed that the Young's and shear moduli decreased linearly with temperature at a rate of −0.021 GPa/K to −0.032 GPa/K, and −0.011 GPa/K to −0.013 GPa/K, respectively. In contrast, the Poisson's ratio was approximately 0.22 for the three materials and was relatively insensitive to temperature. For temperatures >600 K, the elastic moduli decreased more rapidly and resonance peaks broadened, indicating the onset of viscoelastic behavior. The viscoelastic relaxation of the moduli was least for Ce-doped n-type material, for which grain boundary precipitates may inhibit grain boundary sliding which in turn has impor...

Mg2Si is of interest as a thermoelectric (TE) material in part due to its low materials cost, lack of toxic components, and low mass density. However, harvesting of waste heat subjects TE materials to a range of mechanical and thermal stresses. To understand and model the material’s response to such stresses, the mechanical properties of the TE material must be known. The Mg2Si specimens included in this study were powder processed and then sintered via pulsed electrical current sintering. The elastic moduli (Young’s modulus, shear modulus, and Poisson’s ratio) were measured using resonant ultrasound spectroscopy, while the hardness and fracture toughness were examined using Vickers indentation. Also, the Vickers indentation crack lengths were measured as a function of time in room air to determine the susceptibility of Mg2Si to slow crack growth.

Lead chalcogenides such as (Pb0.95Sn0.05Te)0.92(PbS)0.08-0.055%PbI2 have received attention due to their encouraging thermoelectric properties. For the hot pressing (HP) and pulsed electric current sintering (PECS) techniques used in this study, decomposition reactions can generate porosity (bloating). Porosity in turn can degrade electrical, thermal, and mechanical properties. In this study, microstructural observations (scanning electron microscopy) and room-temperature elasticity measurements (resonant ultrasound spectroscopy) were used to characterize bloating generated during post-densification anneals. Although every HP specimen bloated during post-densification annealing, no bloating was observed for the PECS specimens processed from dry milled only powders. The lack of bloating for the annealed PECS specimens may be related to the electrical discharge intrinsic in the PECS process, which reportedly cleans the powder particle surfaces during densification.

Porosity in thermoelectric materials affects the thermal, electrical and mechanical properties of the materials. In this study, the resonant ultrasound spectroscopy technique was used to determine the Young's modulus, E, shear modulus, G, and Poisson's ratio, ν, of 12 hot pressed and five cast polycrystalline specimens of the thermoelectric material LAST (lead–antimony–silver–tellurium) as a function of volume fraction porosity, P, for P ranging from 0.01 to 0.14. A least-squares fit of the Young's and shear moduli data to the relationships E = ED(1 − bPEP) and G = GD(1 − bPGP), respectively yielded ED = 58.4 ± 0.6 GPa and GD = 23.0 ± 0.2 GPa, where ED and GD are the estimated Young's modulus and shear modulus at room temperature for theoretically dense specimens, respectively. The unitless, material-dependent constants bPE and bPG were bPE = 3.5 ± 0.2 and bPG = 3.5 ± 0.2.

In this study, we focus on the room-temperature mechanical properties of LAST (Pb–Sb–Ag–Te) materials fabricated using casting with slow-cool temperature profiles (cooling rate 5°C h−1). The higher biaxial flexural strength is potentially beneficial for the mechanical integrity of thermoelectric devices.

In the open literature, reports of mechanical properties are limited for semiconducting thermoelectric materials, including the temperature dependence of elastic moduli. In this study, for both cast ingots and hot-pressed billets of Ag-, Sb-, Sn- and S-doped PbTe thermoelectric materials, resonant ultrasound spectroscopy (RUS) was utilized to determine the temperature dependence of elastic moduli, including Young's modulus, shear modulus and Poisson's ratio. This study is the first to determine the temperature-dependent elastic moduli for these PbTe-based thermoelectrics, and among the few determinations of elasticity of any thermoelectric material for temperatures above 300 K. The Young's modulus and Poisson's ratio, measured from room temperature to 773 K during heating and cooling, agreed well. Also, the observed Young's modulus, E, versus temperature, T, relationship, E(T) = E 0(1–bT), is consistent with predictions for materials in the range well above the Debye temperature. A nanoindentation study o...