Abstract No.:
5344

 Scheduled at:
Friday, June 09, 2017, Hall 14 11:00 AM
Electronics & Sensoric


 Title:
The evolution of thermal spray as additive manufacturing technology of TEGs: How far can we go?

 Authors:
Maria Barbosa* / Fraunhofer IWS, Germany
Maria Barbosa / Fraunhofer IWS, TU Dresden, Germany
Filofteia-Laura Toma/ Fraunhofer IWS, Germany
Christoph Leyens/ Fraunhofer IWS, TU Dresden, Germany

 Abstract:
The evolution of thermal spray as an additive manufacturing technology for the fabrication of thermoelectrical generators (TEGs) will be presented in this contribution. Thermal spray allows for the deposition of a multi-layered coating containing all the relevant materials for a TEG with one single technology. Moreover, it brings flexibility in form and geometry due to the possibility of depositing the TEG directly on the heat source. It has first been explored as an alternative manufacturing technology in the early 90s and been gaining interest since then. A materials concept and the steps required to fabricate a thermoelectric device will be presented, as well as the required strategy to overcome the challenges associated with the processing materials by thermal spray and combining functional coatings of different materials including the bondcoat, the insulating coating, the p-type semiconductor ( Ca2Fe2O5), the n-type semiconductor (TiOx), the diffusion barrier coating, the filling coating and the electrical conductive coating. TEG (50 x 50 mm²), composed of eight different coatings, were successfully developed by using different thermal spray processes and special masking systems. The feasibility of the generator was tested in industrial environment. The process chain has the potential to be optimized in order to manufacture TEGs in a cost-effective way at an industrial scale. New approaches and alternative materials will be discussed.

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