Structural Reliability Evaluation of Thermoelectric Generator Modules: Influence of End Conditions, Leg Geometry, Metallization, and Processing Temperatures

Karri, Naveen K.; Mo, Changki

doi:10.1007/s11664-018-6505-1

Title: Structural Reliability Evaluation of Thermoelectric Generator Modules: Influence of End Conditions, Leg Geometry, Metallization, and Processing Temperatures

Journal Article · Wed Jul 18 00:00:00 EDT 2018 · Journal of Electronic Materials

DOI:https://doi.org/10.1007/s11664-018-6505-1· OSTI ID:1843224

^[1]; Mo, Changki ^[2]

Washington State University Tri-Cities, Richland, WA (United States); Pacific Northwest National Lab. (PNNL), Richland, WA (United States)
Washington State University Tri-Cities, Richland, WA (United States)

Structural reliability of thermoelectric generators (TEGs) in medium to high temperature applications still remains a challenge. Currently there are no established standards for evaluating the thermomechanical reliability of TEGs during new material and module development phases in the industry. In this work we implemented a procedure for evaluating the reliability of brittle TE materials based on the common practice in the ceramics industry. The probabilistic thermomechanical reliability of TEG couples and modules is evaluated using Weibull analysis. Finite element simulations were carried out to study the influence of TEG couple parameters such as element geometry, dimensions, spacing, metallization thickness, and processing conditions on the stresses, and the structural reliability evaluations are conducted based on the TE element stresses. We report results showed that the boundary conditions and processing temperatures have significant influence on the element and metallization stresses and overall device reliability. The external compressive load significantly enhanced structural reliability. Results also showed that among geometrical parameters the element length has a dominating influence on the element stresses compared to the leg cross-sectional shapes. The cross-section geometry of legs showed considerable effect at shorter lengths and the influence diminished with increased lengths. The proposed approach for evaluating the structural reliability could be integrated with performance optimization techniques for developing optimal and reliable TEG devices.

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Research Organization:: Pacific Northwest National Lab. (PNNL), Richland, WA (United States)

Sponsoring Organization:: USDOE

Grant/Contract Number:: AC05-76RL01830

OSTI ID:: 1843224

Report Number(s):: PNNL-SA-132724

Journal Information:: Journal of Electronic Materials, Vol. 47, Issue 10; ISSN 0361-5235

Publisher:: SpringerCopyright Statement

Country of Publication:: United States

Language:: English

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Title: Structural Reliability Evaluation of Thermoelectric Generator Modules: Influence of End Conditions, Leg Geometry, Metallization, and Processing Temperatures

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