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Starting from bismuth, tellurium and selenium chunks, n-type Bi2Te3−xSex (x ⩽ 0.3) alloys were obtained by melt spinning (MS) combined with a resistance pressing sintering (RPS) process. The phases, microstructures and compositions of the samples were evaluated by x-ray diffraction, field emission scanning electron microscopy, and energy dispersive x-ray spectroscopy during each step in the preparation process, respectively. The influences of Se doping, MS and RPS processes on the thermoelectric (TE) properties of Bi2Te3−xSex alloys were investigated in detail. The Bi2Te3−xSex powders could be well compacted by the RPS process and the relative densities of the bulks prepared by RPS were all higher than 96%. The partially oriented lamellar structure could be observed at some regions of the samples prepared by RPS, and the monolayer thickness of the lamellar structure in the MS-RPS samples was smaller than that in the smelting-RPS sample. The MS process was confirmed as an excellent method to obtain fine microstructures and low lattice thermal conductivity for the TE materials. All evidence about electrical and thermal transport properties suggested that suitably increasing the Se content could effectively improve the ZT value. The maximum ZT value of 0.84 was obtained for the Bi2Te2.7Se0.3 prepared by MS-RPS at 423 K. As opposed to the conventional hot pressing and spark plasma sintering, the RPS method introduced here is more suitable for practical industrial application due to its cost saving and high efficiency. [ABSTRACT FROM AUTHOR]

Highlights: [•] Resistance pressing sintering introduced firstly into thermoelectric materials. [•] The locally oriented lamellar structures were obtained in Bi0.44Sb1.56Te3 alloys. [•] The maximum ZT value of 1.17 was obtained for the Bi0.44Sb1.56Te3 alloys. [•] Resistance pressing sintering was more suitable for industrial application. [ABSTRACT FROM AUTHOR]