Calcium cobaltite (Ca3Co4O9) is
a promising p-type thermoelectric oxide material. Here, we present
an approach to optimize the thermoelectric performance of Ca3Co4O9 by controlling the chemical composition
and fabrication process. Ca3–x
Bi
x
Co3.92O9+δ (0.1
≤ x ≤ 0.3) and Ca2.7Bi0.3Co
y
O9+δ (3.92
≤ y ≤ 4.0) ceramics were prepared by
Spark Plasma Sintering (SPS). Stoichiometric mixtures of raw materials
were combined and calcined at 1203 K for 12 h, followed by SPS at
1023 K for 5 min at 50 MPa. The samples were subsequently annealed
at 1023 or 1203 K for 12 h in air. XRD and HRTEM analyses confirmed
the formation of the cobaltite misfit phase with minor amounts of
secondary phases; SEM-EDS showed the presence of Bi-rich and Co-rich
secondary phases. After annealing at 1203 K, the secondary phases were significantly reduced.
By controlling the cobalt deficiency and level of bismuth substitution,
the electrical conductivity was enhanced without degrading Seebeck
coefficients, promoting a high power factor of 0.34 mW m–1 K–2 at 823 K (parallel to the ab planes, //ab). Due to enhanced phonon scattering, the thermal conductivity
was reduced by 20%. As a result, a highly competitive ZT(//ab) of
0.16 was achieved for Ca2.7Bi0.3Co3.92O9+δ ceramics at 823 K.