Performance analysis of cascaded thermoelectric converters for advanced radioisotope power systems

Advanced radioisotope power systems (ARPSs) for future planetary missions require higher conversion efficiency than the state-of-the-art (SOA) SiGe thermoelectric converter in order to decrease system mass and reduce mission cost. The performance of three cascaded thermoelectric converters (CTCs) for potential use in ARPSs is investigated at heat rejection temperatures of 375, 475 and 575 K and input thermal powers of 1, 2 and 3 Wth. These CTCs have top SiGe unicouples that are thermally, but not electrically, coupled to bottom unicouples having one of the following compositions: (a) TAGS-85 (p-leg) and 2N-PbTe (n-leg); (b) CeFe3.5Co0.5Sb12 (p-leg) and CoSb3 (n-leg); and (c) segmented p-leg of CeFe3.5Co0.5Sb12 and Zn4Sb3 and n-leg of CoSb3. The top and bottom unicouples in the CTCs are of the same length (10 mm), but the optimized cross-sectional areas of the n- and p-legs for maximum efficiency are different. The nominal hot junction temperature of the top SiGe unicouples at their peak efficiencies is 1273 K and that of the cold junction is 780 K when the bottom unicouple is of composition (a) and 980 K for compositions (b) and (c). The hot junction temperatures of the bottom unicouples are taken 20 K lower than the cold junctions of the top unicouples, but the input thermal powers to the former are the same as those rejected by the latter. Assuming zero side heat losses and a contact resistance of 150 μΩ cm2 per leg in the top and bottom unicouples, the calculated peak efficiencies of the CTCs vary from 9.43% to 14.35%. These efficiencies are 40-113% higher, respectively, than that of SOA SiGe (∼6.5%) when operating at the cold junction temperature of 566 K and the same hot junction temperature (1273 K) and contact resistance per leg. Decreasing this resistance to a realistic value of 50 μΩ cm2 per leg increases the peak efficiencies of the CTCs by 0.5-0.9 percentage points to 9.93-15.25%.