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Engineering Reports
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https://dx.doi.org/10.15488/13...
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Engineering Reports
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Experimental application of a laser‐based manufacturing process to develop a free customizable, scalable thermoelectric generator demonstrated on a hot shaft

Authors: Marvin Abt; Katharina Kruppa; Mario Wolf; Armin Feldhoff; Ludger Overmeyer;

Experimental application of a laser‐based manufacturing process to develop a free customizable, scalable thermoelectric generator demonstrated on a hot shaft

Abstract

AbstractGeometry, design, and processing in addition to the thermoelectric material properties have a significant influence on the economic efficiency and performance of thermoelectric generators (TEGs). While conventional BULK TEGs are elaborate to manufacture and allow only limited variations in geometry, printed TEGs are often restricted in their application and processing temperature due to the use of organic materials. In this work, a proof‐of‐concept for fabricating modular, customizable, and temperature‐stable TEGs is demonstrated by applying an alternative laser process. For this purpose, low temperature cofired ceramics substrates were coated over a large area, freely structured and cut without masks by a laser and sintered to a solid structure in a single optimized thermal post‐processing. A scalable design with complex geometry and large cooling surface for application on a hot shaft was realized to prove feasibility. Investigations on sintering characteristics up to a peak temperature of 1173 K, thermoelectric material properties and temperature distribution were carried out for a Ca3Co4O9/Ag‐based prototype and evaluated using profilometer, XRD, and IR measurements. For a combined post‐processing, an optimal sintering profile could be determined at 1073 K peak temperature with a 20 min holding time. Temperature gradients of up to 100 K could be achieved along a thermocouple. A single TEG module consisting of 12 thermocouples achieved a maximum power of 0.224 μW and open‐circuit voltage of 134.41 mV at an average hot‐side temperature of 413.6 K and temperature difference of 106.7 K. Three of these modules combined into a common TEG with a total of 36 thermocouples reached a maximum power of 0.58 K and open‐circuit voltage of 319.28 mV with a lesser average hot‐side temperature of 387.8 K and temperature difference of 83.4 K.

Keywords

Ca3Co4O9, energy harvesting, LTCC, Dewey Decimal Classification::600 | Technik::620 | Ingenieurwissenschaften und Maschinenbau, thermoelectric generator, QA75.5-76.95, Engineering (General). Civil engineering (General), Dewey Decimal Classification::600 | Technik, printed ceramics, Electronic computers. Computer science, laser structuring, TA1-2040

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citations
This is an alternative to the "Influence" indicator, which also reflects the overall/total impact of an article in the research community at large, based on the underlying citation network (diachronically).
BIP!Citations provided by BIP!
popularity
This indicator reflects the "current" impact/attention (the "hype") of an article in the research community at large, based on the underlying citation network.
BIP!Popularity provided by BIP!
influence
This indicator reflects the overall/total impact of an article in the research community at large, based on the underlying citation network (diachronically).
BIP!Influence provided by BIP!
impulse
This indicator reflects the initial momentum of an article directly after its publication, based on the underlying citation network.
BIP!Impulse provided by BIP!
3
Top 10%
Average
Average
gold