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Technological approach for a full thermally sprayed thermoelectric generator

: Puschmann, Roberto; Barbosa, Maria M.; Scheitz, Stefan; Berger, Lutz-Michael; Toma, Filofteia-Laura; Leyens, Christoph; Beyer, Eckhard

Deutscher Verband für Schweißen und Verwandte Verfahren e.V. -DVS-; The Thermal Spray Society -TSS-; International Institute of Welding -IIW-:
ITSC 2014, International Thermal Spray Conference & Exposition : Abstracts (including manuscripts on CD-ROM) of the conference in Barcelona, Spain, on May 21-23, 2014
Düsseldorf: DVS Media, 2014 (DVS-Berichte 302)
ISBN: 978-3-87155-574-9
International Thermal Spray Conference & Exposition (ITSC) <2014, Barcelona>
Conference Paper
Fraunhofer IWS ()
thermisches Spritzen; thermoelektrischer Generator; Sprühkompaktieren; Prozessoptimierung

Thermal spraying represents a potential efficient technology for the manufacture thermoelectric generators (TEG) in order to extend their use for waste heat recovery at large surfaces and high service temperatures, but meets challenges from both material and technological side. At least four types of materials are required for the manufacture of a TEG, which can be prepared as a complex thermally sprayed multilayer. These are electrical insulators, electrical conductors and p- and n-semiconductors thermoelectrically active materials. In this paper, different thermal spray processes (APS, HVOF, HVAF) were used to develop a manufacturing technology for TEG. A particular challenge is to obtain a perfect bonding between the different coatings, which is most difficult for spraying metallic coatings onto previously deposited ceramic coatings. In addition, for the manufacture of a fully thermally sprayed TEG, several layers, such as the n- and p-semiconductors, have to be located on the same height level in the multilayer. This requires the development of appropriate masks. After process optimization for each individual material for service in the multilayer system, TEG modules were successfully manufactured.