Realizing High Conversion Efficiency in All-ZrCoSb-Based Half-Heusler Thermoelectric Power Generators

ZrCoSb-based thermoelectric materials exhibit promising potential for power generation applications due to their high performance in both p- and n-type constituents. In this work, a newly developed all-ZrCoSb-based module achieves a maximum conversion efficiency of ~9.3% at a temperature difference of 668 K. This high conversion efficiency is enabled by the enhanced average thermoelectric properties for both types of ZrCoSb-based materials via Bi alloying and Sn/Ni doping. The hole and electron carrier concentrations were tuned to match the theoretically predicted optimized values, contributing to high weight mobility and power factor. Additionally, the increased mass and strain field fluctuations enhance point defect scattering, leading to a significant reduction in the lattice thermal conductivity of ZrCoSb. Consequently, peak zT values of ~1.2 and ~1.0 at 973 K were respectively obtained in p-type ZrCo(Sb0.5Bi0.5)0.85Sn0.15 and n-type ZrCo0.85Ni0.15Sb0.5Bi0.5, resulting in high average zT values of ~0.75 and ~0.51 in the temperature of 300 to 973 K. This work underscores the significant potential of all-ZrCoSb-based half-Heuslers in waste heat recovery.