Chun I. Wu

High-performance bulk thermoelectrics with all-scale hierarchical architectures

With about two-thirds of all used energy being lost as waste heat, there is a compelling need for high-performance thermoelectric materials that can directly and reversibly convert heat to electrical energy. However, the practical realization of thermoelectric materials is limited by their hitherto low figure of merit, ZT, which governs the Carnot efficiency according to the second law of thermodynamics. The recent successful strategy of nanostructuring to reduce thermal conductivity has achieved record-high ZT values in the range 1.5–1.8 at 750–900 kelvin, but still falls short of the generally desired threshold value of 2. Nanostructures in bulk thermoelectrics allow effective phonon scattering of a significant portion of the phonon spectrum, but phonons with long mean free paths remain largely unaffected. Here we show that heat-carrying phonons with long mean free paths can be scattered by controlling and fine-tuning the mesoscale architecture of nanostructured thermoelectric materials. Thus, by considering sources of scattering on all relevant length scales in a hierarchical fashion—from atomic-scale lattice disorder and nanoscale endotaxial precipitates to mesoscale grain boundaries—we achieve the maximum reduction in lattice thermal conductivity and a large enhancement in the thermoelectric performance of PbTe. By taking such a panoscopic approach to the scattering of heat-carrying phonons across integrated length scales, we go beyond nanostructuring and demonstrate a ZT value of ∼2.2 at 915 kelvin in p-type PbTe endotaxially nanostructured with SrTe at a concentration of 4 mole per cent and mesostructured with powder processing and spark plasma sintering. This increase in ZT beyond the threshold of 2 highlights the role of, and need for, multiscale hierarchical architecture in controlling phonon scattering in bulk thermoelectrics, and offers a realistic prospect of the recovery of a significant portion of waste heat.

High Performance Thermoelectrics from Earth-Abundant Materials: Enhanced Figure of Merit in PbS by Second Phase Nanostructures

Lead sulfide, a compound consisting of elements with high natural abundance, can be converted into an excellent thermoelectric material. We report extensive doping studies, which show that the power factor maximum for pure n-type PbS can be raised substantially to ~12 μW cm(-1) K(-2) at >723 K using 1.0 mol % PbCl(2) as the electron donor dopant. We also report that the lattice thermal conductivity of PbS can be greatly reduced by adding selected metal sulfide phases. The thermal conductivity at 723 K can be reduced by ~50%, 52%, 30%, and 42% through introduction of up to 5.0 mol % Bi(2)S(3), Sb(2)S(3), SrS, and CaS, respectively. These phases form as nanoscale precipitates in the PbS matrix, as confirmed by transmission electron microscopy (TEM), and the experimental results show that they cause huge phonon scattering. As a consequence of this nanostructuring, ZT values as high as 0.8 and 0.78 at 723 K can be obtained for nominal bulk PbS material. When processed with spark plasma sintering, PbS samples with 1.0 mol % Bi(2)S(3) dispersion phase and doped with 1.0 mol % PbCl(2) show even lower levels of lattice thermal conductivity and further enhanced ZT values of 1.1 at 923 K. The promising thermoelectric properties promote PbS as a robust alternative to PbTe and other thermoelectric materials.

High thermoelectric performance via hierarchical compositionally alloyed nanostructures.

Previous efforts to enhance thermoelectric performance have primarily focused on reduction in lattice thermal conductivity caused by broad-based phonon scattering across multiple length scales. Herein, we demonstrate a design strategy which provides for simultaneous improvement of electrical and thermal properties of p-type PbSe and leads to ZT ~ 1.6 at 923 K, the highest ever reported for a tellurium-free chalcogenide. Our strategy goes beyond the recent ideas of reducing thermal conductivity by adding two key new theory-guided concepts in engineering, both electronic structure and band alignment across nanostructure-matrix interface. Utilizing density functional theory for calculations of valence band energy levels of nanoscale precipitates of CdS, CdSe, ZnS, and ZnSe, we infer favorable valence band alignments between PbSe and compositionally alloyed nanostructures of CdS1-xSex/ZnS1-xSex. Then by alloying Cd on the cation sublattice of PbSe, we tailor the electronic structure of its two valence bands (light hole L and heavy hole Σ) to move closer in energy, thereby enabling the enhancement of the Seebeck coefficients and the power factor.

Raising the Thermoelectric Performance of p-Type PbS with Endotaxial Nanostructuring and Valence-Band Offset Engineering Using CdS and ZnS

We have investigated in detail the effect of CdS and ZnS as second phases on the thermoelectric properties of p-type PbS. We report a ZT of ~1.3 at 923 K for 2.5 at.% Na-doped p-type PbS with endotaxially nanostructured 3.0 at.% CdS. We attribute the high ZT to the combination of broad-based phonon scattering on multiple length scales to reduce (lattice) thermal conductivity and favorable charge transport through coherent interfaces between the PbS matrix and metal sulfide nanophase precipitates, which maintains the requisite high carrier conductivity and the associated power factor. Similar to large ionically bonded metal sulfides (ZnS, CaS, and SrS), the covalently bonded CdS can also effectively reduce the lattice thermal conductivity in p-type PbS. The presence of ubiquitous nanostructuring was confirmed by transmission electron microscopy. Valence and conduction band energy levels of the NaCl-type metal sulfides, MS (M = Pb, Cd, Zn, Ca, and Sr) were calculated from density functional theory to gain insight into the band alignment between PbS and the second phases in these materials. The hole transport is controlled by band offset minimization through the alignment of valence bands between the host PbS and the embedded second phases, MS (M = Cd, Zn, Ca, and Sr). The smallest valence band offset of about 0.13 eV at 0 K was found between PbS and CdS which is diminished further by thermal band broadening at elevated temperature. This allows carrier transport between the endotaxially aligned components (i.e., matrix and nanostructure), thus minimizing significant deterioration of the hole mobility and power factor. We conclude the thermoelectric performance of the PbS system and, by extension, other systems can be enhanced by means of a closely coupled phonon-blocking/electron-transmitting approach through embedding endotaxially nanostructured second phases.

Thermoelectrics with Earth Abundant Elements: High Performance p-type PbS Nanostructured with SrS and CaS

We report high thermoelectric performance in nanostructured p-type PbS, a material consisting of highly earth abundant and inexpensive elements. The high level of Na doping switched intrinsic n-type PbS to p-type and substantially raised the power factor maximum for pure PbS to ~9.0 μW cm(-1) K(-2) at >723 K using 2.5 at. % Na as the hole dopant. Contrary to that of PbTe, no enhancement in the Hall coefficient occurs at high temperature for heavily doped p-type PbS, indicating a single band model and no heavy hole band. We also report that the lattice thermal conductivity of PbS can be greatly reduced by adding SrS or CaS, which form a combination of a nanostructured/solid solution material as determined by transmission electron microscopy. We find that both nanoscale precipitates and point defects play an important role in reducing the lattice thermal conductivity, but the contribution from nanoscale precipitates of SrS is greater than that of CaS, whereas the contribution from point defects in the case of CaS is greater than that of SrS. Theoretical calculations of the lattice thermal conductivity based on the modified Callaway model reveal that both nanostructures and point defects (solid solution) effectively scatter phonons in this system. The lattice thermal conductivity at 723 K can be reduced by ~50% by introducing up to 4.0 at. % of either SrS or CaS. As a consequence, ZT values as high as 1.22 and 1.12 at 923 K can be achieved for nominal Pb(0.975)Na(0.025)S with 3.0 at. % SrS and CaS, respectively. No deterioration was observed after a 15 d annealing treatment of the samples, indicating the excellent thermal stability for these high performance thermoelectrics. The promising thermoelectric properties of nanostructured PbS point to a robust low cost alternative to other high performance thermoelectric materials.

High ZT in p-Type (PbTe)1–2x(PbSe)x(PbS)x Thermoelectric Materials

Lead chalcogenide thermoelectric systems have been shown to reach record high figure of merit values via modification of the band structure to increase the power factor or via nanostructuring to reduce the thermal conductivity. Recently, (PbTe)1-x(PbSe)x was reported to reach high power factors via a delayed onset of interband crossing. Conversely, the (PbTe)1-x(PbS)x was reported to achieve low thermal conductivities arising from extensive nanostructuring. Here we report the thermoelectric properties of the pseudoternary 2% Na-doped (PbTe)1-2x(PbSe)x(PbS)x system. The (PbTe)1-2x(PbSe)x(PbS)x system is an excellent platform to study phase competition between entropically driven atomic mixing (solid solution behavior) and enthalpy-driven phase separation. We observe that the thermoelectric properties of the PbTe-PbSe-PbS 2% Na doped are superior to those of 2% Na-doped PbTe-PbSe and PbTe-PbS, respectively, achieving a ZT ≈2.0 at 800 K. The material exhibits an increased the power factor by virtue of valence band modification combined with a very reduced lattice thermal conductivity deriving from alloy scattering and point defects. The presence of sulfide ions in the rock-salt structure alters the band structure and creates a plateau in the electrical conductivity and thermopower from 600 to 800 K giving a power factor of 27 μW/cmK(2). The very low total thermal conductivity values of 1.1 W/m·K of the x = 0.07 composition is accounted for essentially by phonon scattering from solid solution defects rather than the assistance of endotaxial nanostructures.

High-performance tellurium-free thermoelectrics: All-scale hierarchical structuring of p-type PbSe-MSe systems (M = Ca, Sr, Ba)

We present a systematic study of the characterization and thermoelectric properties of nanostructured Na-doped PbSe embedded with 1-4% MSe (M = Ca, Sr, Ba) phases as endotaxial inclusions. The samples were powder-processed by the spark plasma sintering technique, which introduces mesoscale-structured grains. The hierarchical architectures on the atomic scale (Na and M solid solution), nanoscale (MSe nanoprecipitates), and mesoscale (grains) were confirmed by transmission electron microscopy. These structures produce a great reduction in the lattice thermal conductivity relative to pristine PbSe without appreciably affecting the power factor. The lattice thermal conductivity can be reduced by up to ∼29% when the second phase is added. The highest ZT value achieved was ∼1.3 at 923 K for both 2% SrSe-and 3% BaSe-containing samples, while the sample containing 4% CaSe showed a ZT value of ∼1.2 at 923 K. The optimal samples have hole carrier concentration of 1-2 × 10(20) cm(-3). We attribute the high ZT values to the combination of broad-based phonon scattering on multiple length scales and favorable charge transport through coherent interfaces between the PbSe matrix and MSe.

Characterization of dry milled powders of LAST (lead–antimony–silver–tellurium) thermoelectric material

Although thermoelectric (TE) materials are often fabricated as cast ingots, there has been recent interest in the powder processing of these materials. Cast TE materials typically have grain sizes as large as several hundred microns, but powder processing (grinding, milling and then sintering) can produce dense specimens with a reduced grain size, an improved mechanical integrity and enhanced TE properties. In the TE literature when powder processing is employed, little or no description is provided of the powder processing techniques and the powder processing parameters are either not characterized or only a mean particle size is given. In this study, powders milled from solid cast ingots of the TE compound LAST (lead–antimony–silver–tellurium) were characterized via Coulter Counter, to measure the mean powder particle size and the size distribution, scanning electron microscopy (SEM), to examine the powder particle morphology, and X-ray diffraction (XRD), to detect possible phase changes or amorphization. The impurity levels in the milled powders were examined by wear rate measurements on the milling media, as well as by energy dispersive X-ray analysis and inductively coupled plasma measurements.

Bloating in (Pb0.95Sn0.05Te)0.92(PbS)0.08-0.055%PbI2 Thermoelectric Specimens as a Result of Processing Conditions

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.

Transport behavior and thermal conductivity reduction in the composite system PbTe-Pb-Sb

We report the synthesis of nanostructured composite PbTe with excess Pb and Sb metal inclusions. Scanning and transmission electron microscopy reveal these inclusions in both the nano- and macroscales. The electrical conductivity and Seebeck coefficient dependence on temperature show unusual trends which depend on the inclusion Pb/Sb ratio. Several ratios showed marked enhancements in power factor at 700 K. The thermal conductivity of these composites is reported.