Development of high-strength Fe2VAl thermoelectric module designed for a motorcycle

A thermoelectric module was constructed using p-type Fe₂V_0.9Ti_0.1Al and n-type Fe₂VAl_0.9Si_0.1 sintered alloy prepared by pulse-current sintering. The thermoelectric power factor of the p- and n-type material was 1.6 and 4.1 mW/mK², respectively. These sintered alloys were connected in series with copper electrode. The connection was made by Joule heating under a high pressure without electrically conductive jointing materials, such as solder and Ag paste. The shear strength of the bonding was estimated to be 100 MPa. The electrical resistance of the bonding was negligible small compared to that of alloy. The conventional pi type thermoelectric module consisting 12 pairs of the p- and n-type Fe₂VAl alloy generated 829 mW on a hot plate of 573 K in air. A fin type module was constructed to demonstrate the power generation using waste heat and relative wind of a running motorcycle. The module generated 54 mW at 128 mV under the temperature difference of 50 K produced by a hot plate and air flow.