3.1. Laser processing
All BST samples in this study were LP using the ORLAS Creator metal 3D printer.
Figure 4a presents the interior chamber of the printer where the samples were processed.
This figure displays the printer’s basic operation: The powder stored on the powder feeding platform is uniformly distributed on the building platform by the powder dispersion arm, and any excess is stored for later recycling. The laser beam, as it emerges from the glass, sequentially melts the powder layer by layer, thereby creating the printed structure. All procedures take place in an argon atmosphere, which is controlled by an oxygen sensor on the chamber’s top side. In our case, the BST samples were placed on the building platform (
Figure 4b) and their positions were aligned using the markers produced on the platform (as described in
Section 2). To process all sides of the samples, the following approach was implemented (
Figure 4c): The disk pellets were first processed on one side and the building platform was then withdrawn from the printer in order to flip all samples and process the opposite side. Following completion of the cross section areas, the disk pellets were put upright and processed on the perimetrical side. The task was carried out 3 times by turning the samples 120 degrees clockwise. In the case of the rectangular BST samples, similar technique was followed. Here, because all sides were flat and the samples did not fall or turn, the processing was easier.
Figure 5a and
Figure 5f show LP BST samples with SS values ranging from [800 - 1800] mm/s and a step of 200 mm/s, and
Figure 5g presents schematically the laser scanning strategy that was implemented. Based on our prior experience with other materials, the double pass strategies provided smoother, less porous layers [
51,
52]. The samples displayed here have only been processed once. According to this figure, the surface of the sample melts and solidifies throughout the LP procedure, resulting in randomly dispersed "canyon" form patterns. As the SS grows, the number of these "canyons" increases but their size decreases, resulting in considerably smoother surfaces.
Figure 6a and
Figure 6b show SEM images of the BST samples with SS = 600 mm/s and SS = 1600 mm/s (SS1600), respectively. The change in the number and size of the "canyons" as the SS increases is more obvious here. More specifically, from the standpoint of surface energy this behavior can be expected since SS is inversely related to energy (E = P / (SS * HD) where P is the laser beam power, SS the scan speed and HD the hatch distance). As a result, higher energy levels deform the surface of the sample on a bigger scale by causing larger melted "canyons", as can be seen in
Figure 6a. A magnified image of the surface of the SS1600 sample presented in
Figure 6c. The deformation of the melted surface is considerably clearer here, with pores of varying size and shape being randomly scattered. At this point it has to be mentioned that, during the LP procedure a considerably number of samples were shuttered (thermal shocked) as they were parameterized (the disk pellet shown in
Figure 5a was cracked from the first round of the LP cycles). Specifically, the disk pellet samples with SS values less than 1000 mm/s were shuttered at some time during the LP cycles shown in
Figure 4c, whereas the rectangular samples were shuttered in SS values less than 1200 mm/s. This was tested twice with a new set of BST samples to see if they shutter randomly or not. As a result, a complete set of samples (disk and rectangular pellets) that "survived" the LP procedure and could be thermoelectrically characterized, had SS values higher than 1200 mm/s.
Figure 7a presents a rectangular BST sample that was LP with the following parameters: SS = 1600 mm/s, P = 25 W, HD = 50 µm, as well as sliced pieces of its disk pellet. These samples were cut before processing using a low RPM diamond wheel cutter, revealing the difference between treated and untreated surfaces.
Figure 4c schematically displays the LP cycles that were followed for the current shape.
Figure 7c and
Figure 7d show SEM images of the same sample’s shuttered cross section after the first LP cycle, revealing the processed and unprocessed surfaces, respectively. The surface processed image (
Figure 7c) distinguishes between the sintered (right side of the image) and melted (left side of the image) phases of the material, with the border between them clearly visible. The same border can be seen in
Figure 7b, which is the magnified area of the red inset in
Figure 7c. The mechanics of the material’s surface melting, as well as the size of its effect, are better conveyed in these images. Specifically, the energy absorbed by the material in the form of heat melts the sintered particles, resulting in a bulk crust with a certain average thickness. This crust forms the walls of the "canyons" seen before. The size of the walls reduces as the absorbed energy drops, while their number increases. This increase on the surface area of the walls, resulting in a homogeneous channel of melted material on the surface of the samples. These channels of different material states primarily impact the electrical properties of the sample, which will be discussed in the next part.
Figure 8 showcases the X-ray diffraction profiles of the BST powder employed, along with its associated JCPDS diagram, and highlights the in-plane orientation of both the HP and LP samples. Here the SS1600 LP sample was examined. The X-ray diffraction analyses were performed over an angular span of 10-60 degrees, utilizing an angular step size of 0.02 degrees and a scan rate of 1 degree per minute. Operating conditions included an acceleration voltage of 30 kV and a beam current of 15 mA, generating Cu-Kα radiation (λ = 1.5406 Å). Upon comparing the patterns, it becomes evident that the intensity of the (0015) peak is notably greater in the in-plane direction, particularly in the LP sample where it appears significantly higher. Given that the LP state involves a molten crust on the sample’s surface, the orientation of (0015) is more favorable compared to the sintered state. Furthermore, in the LP sample, there is a noticeable enhancement in the sharpness of various X-ray peaks compared to the HP sample. Additionally, the qualitative and quantitative alterations in the chemical composition of the SS1600 sample pre- and post-laser processing are observable through the energy-dispersive X-ray spectroscopy (EDXS) analysis presented in
Figure 9. The analysis reveals the evident presence of all three elements in the alloy, accompanied by their respective radiated energies and percentage atomic values as detailed in the inset. The outcomes suggest that there is no discernible alteration in the chemical state of the alloy following the LP procedure.
3.2. Thermoelectric characterization
The TE characterization was carried out by electrically characterizing the rectangular shape samples and thermally characterizing the disk-shaped samples.
Figure 10 presents 3D color-maps of TE characteristics as a function of temperature and SS. Here, the temperature range is [300-500] K and the SS range is [1400 - 1600] mm/s, and the legend on the right side of each graph colorizes the values of each TE property. Starting with the property of thermal conductivity, as shown in
Figure 10a, there is a minimum for all values of SS in the temperature area of [325-350] K, which is also the material’s interest temperature range. At the same time, the values of thermal conductivity in this area (red inset) appear to be mainly steady versus SS, as shown in
Figure 10b, which is the XY view of
Figure 10a. In particular, the average minimum value of thermal conductivity versus SS in this area is
κ = 0.77 Wm
−1K
−1, with a 1.8% variation.
In terms of electrical conductivity, however, it is clear from
Figure 10c that the LP procedure has a considerable impact. More specifically, there is a peak close to the SS = 1600 mm/s in practically all temperature ranges, with higher values at lower temperatures. This maximum has a value of σ = 425 Scm
−1 in the temperature range of interest. The Seebeck coefficient, on the other hand, exhibits exactly the opposite trend, which was to be expected considering that increases in electrical conductivity often impact the Seebeck coefficient in the opposite direction due to increases in the thermal conductivity of electrons. According to
Figure 10d, a minima for the Seebeck coefficient with an approximately average value of S = 233 µVK
−1 occurs near to the SS value of 1600 mm/s within the temperature range of interest, which, however, continuously expands up to 375 K before starting down streaming. The power factor 3D graph is presented in
Figure 10e, which is the product of electrical conductivity and the Seebeck coefficient via the equation PF = σS
2. According to this graph, the PF appears to rise approximately linearly as the SS increases, with an average slope of S
avg =
mW m
−1K
−2 / mm s
−1 within the temperature range of interest. This represents a notably gradual increase, reflecting the limited influence of SS on PF, which is intricately connected to the opposing behaviors of the two electrical parameters: electrical conductivity and Seebeck coefficient. The same holds for the figure of merit ZT, shown in
Figure 10f, which is correlate to the other properties via the relationship ZT = PF/µ. Here, the slope was determined using the highest ZT values and is ZT
slope =
1 / mm s
−1.
Figure 11 displays the comparative analysis of the TE properties. It contrasts the LP samples at SS values of 1400 mm/s, 1600 mm/s, and 1800 mm/s with the untreated state (HP sample), which acts as the reference. Regarding thermal conductivity (
Figure 11a), the results indicate that the influence of laser processing is minimal, with deviations less than 0.5%. However, in terms of electrical properties, particularly for the SS1600 sample, the impact is significant. Specifically, the SS1600 sample exhibits an average increase of 12% in electrical conductivity (
Figure 11c) and a 9% reduction in Seebeck coefficient (
Figure 11b) within the relevant temperature range, leading to an average 6.9% decrease in ZT value (
Figure 11e). Additionally, as shown in
Figure 10c, increasing the SS values tends to converge the ZT maximum values to the unprocessed maximum value (ZT = 1.02). This is something that is expected, since as previously stated, increasing SS values reduces total energy absorbed, resulting in smoother but less thick melted layers.
Figure 12 illustrates the discussion of the obtained results for the SS1600 LP sample in relation to the existing literature. The outcomes concerning TE properties are juxtaposed with our prior research [
50] and other investigations [
46,
48] conducted on the same BST alloy. Commencing with the thermal conductivity property denoted by
in
Figure 12a, its values fluctuate between [0.7 - 1.0] Wm
−1K
−1 and reach an absolute minimum of
= 0.78 Wm
−1K
−1 within the temperature span of [325 K - 350 K]. This minimum closely resembles the value obtained in our prior research and stands as the lowest among the comparisons with the other two studies. The Seebeck coefficient, as illustrated in
Figure 12b, demonstrates its peak value across the same temperature range, reaching its maximum value at S
max = 235
V K
−1. followed by a steady rapid decline, and in comparison to all three studies it consistently exhibits the lowest values. However, the electrical conductivity
, depicted in
Figure 12c, exhibits higher values in comparison to our prior research and nearly matches the values found in the study conducted by Jang et al. The data indicates a steady convergence of its values towards the minimum value of
= 2.92 x 10
4 S/m. The power factor of the specimen is derived by combining the Seebeck coefficient and electrical conductivity values using the equation PF =
. As portrayed by the curve in
Figure 12d, there is a continual decrease observed as a function of temperature, without any discernible peaks or valleys, maintaining consistency across all three studies. These values remain unchanged in comparison to our previous research and are notably the lowest among the other two studies.
Ultimately, the figure of merit ZT is depicted in
Figure 12e, computed via the equation ZT = T*PF/
. Observing the curve, a definitive peak with a value of ZT = 0.95 emerges around the temperature of T = 330 K, signifying the optimal operating temperature for the thermoelectric material. In contrast to all three studies, the ZT closely aligns with the curves as they traverse the overall range. Compared to our earlier research, it exhibits a decrease of 6.9%.