A study of interfacial electrical contact resistances of thermoelectric generators for hypersonic vehicles by experimental measurements and two-scale numerical simulations

An enormous amount of aerodynamic heat is produced on the surface of hypersonic vehicles, and the thermoelectric generator (TEG) technique holds the potential to convert aerodynamic heat into electric energy. In a TEG, the micrometer-scale roughness on TE legs and electrodes surfaces leads to the constriction of interfacial electric current and brings about electrical contact resistance (ECR). The heat transfer and conversion processes of a TEG are greatly influenced by such type of ECR. In this work, a TEG includes two ceramic substrates and a middle TE layer is established, and the TE layer consists of insulation material, N- and P-type TE legs and electrodes to connect the TE legs. The ECR and its effects on the TEG performance are studied by two-scale numerical simulations and experimental measurements. First, the practical topography of rough surfaces for TE legs and electrodes is measured, and the micrometer-scale ECR prediction numerical models are established based on the reconstructed topography. An ECR measurement platform is developed and the platform consists of a pressure device, power supply and data acquisition system which are used to provide loading pressures, voltage, and acquisition of electric current and voltage signals, respectively. The ECRs under different temperatures, loading pressures and gap mediums are then predicted and the numerical models are validated by a series of measurements. Second, the TE conversion process of TEG is simulated by a millimeter-scale model including insulation materials, TE legs, electrodes, and equivalent interfacial layers of ECR. The influence of ECR on the TE performance of TEG for the hypersonic vehicle is thus clarified.