Significant variations in figure-of-merit (zT) values between n and p-type silicides impede the thermoelectric performance of cost-effective silicide-based thermoelectric power generators (TEGs). We report a significantly enhanced and compatible zT value in a p-type higher manganese silicide (HMS)-CrSi 2 nanocomposite synthesized using a combination of liquid-phase melt-spinning (MS) and solid-phase spark plasma sintering (SPS). The MS−SPS-processed HMS-CrSi 2 (80−20 wt %) composite material shows substantially enhanced electrical conductivity and a high power factor value. Also, a remarkable enhancement of the HMS-20 wt % CrSi 2 composite materials' zT ≃ 0.92 is realized due to a concurrent reduction in its thermal conductivity (κ). This 2-fold increase in the zT value compared to pure HMS exhibited by the composite material, consisting of nanoscale dimensional grain features, mainly originates from a rapid solidification melt-spinning process. The composite of HMS-CrSi 2 synthesized using the combination of MS and SPS techniques is investigated to realize a high thermoelectric figure-of-merit (zT) value in a p-type thermoelectric material, which is considered a potential compatible counterpart for n-type silicides.

Contact electrodes and their adequate joining are the main bottlenecks in realizing low-cost Mg2(Si,Sn) thermoelectric materials for thermoelectric generator applications. The resistance and diffusion chemistry between the thermoelectric elements and contact electrodes play an essential role in achieving high-performance thermoelectric generators for intermediate-temperature applications. A facile single-step spark plasma sintering process was employed to fabricate Sb-doped Mg2Si0.9Sn0.1 and contact joining simultaneously. The single-step-processed thermoelectric element’s power output characteristics with three different contacts (Ni, MnSi, and FeSi2) were investigated by employing a thermoelectric conversion efficiency evaluation system. Our experimental strategy demonstrated that the single-step processing of Mg2(Si0.9Sn0.1)0.95Sb0.05/Ni joining imparts the lowest internal resistance and high-power output characteristics and eliminates the main obstacle of Mg2(Si,Sn) material integration in thermoelectric power generators.