Periodic Reporting for period 3 - FAST-SMART (FAST and Nano-Enabled SMART Materials, Structures and Systems for Energy Harvesting)
Reporting period: 2023-04-01 to 2024-09-30
Using ambient energy that would otherwise be lost such as heat, light or sound, energy harvesting is well known for its applications in solar cells. Moreover, the technology has numerous new innovative uses, thanks to recent digital trends, including the Internet of Things. The wider implementation of energy-harvesting technologies hinges on the availability of reliable materials that are based on earth-abundant elements and can be processed with efficient manufacturing processes, as well as that can be recycled. The overall goal of the EU-funded FAST-SMART project was to apply novel manufacturing techniques on a large scale which are recently developed by project members for synthesising smart nanomaterials and converting them into functional structures/components for energy harvesting. The development of new piezoelectric (PE) and thermoelectric (TE) materials and energy harvesting structures using earth-abundant elements and highly efficient manufacturing processes aimed to enhance material-supply resilience, reduce impacts on the environment, improve processing efficiency, and reduce overall material and product costs.
The main project reuslts include: two (2) kinds of new PE and TE materials, one (1) new machine system and one new tool-system (1) for powder sintering and part manufacturing, one (1) new material-recycling procedure, three (3) surface coating/treatments techniques/procedures, and three (3) new types of energy harvesters.
(I). High-quality Nano Lead-free Piezoelectric BCZT with favourable dielectric response, low losses (tan delta), low thermal conductivity. A pilot line has been established, presenting advantages over the solid-state reaction with lower reaction time (10 times smaller, comparing to the current state of the art) and low energy consumption.
(II). The process of Solid-state Mechanochemical Synthesis of Thermoelectric Materials at the pilot industrial scale has been established, and validated for productivity of 10kg per day of powder. Seven different TE materials have been synthesised with this process, Hafnium-free Half Heuslers, Lithium-doped P-type silicide, and Bismuth-doped Magnesium Antimonide.
(III). The world first, double-acting, high-precision FAST-sintering press has been constructed and tested, which enables highly precise force, heating and cooling controls, with a fully automated mode for inert gas supply, die-system transfer, sintering, cooling and chamber door-system management.
(IV). A new FAST-sintering die design has been implemented for high-temperature sintering enabling focusing the high sintering temperature mainly at the sintering areas and hence, reducing the heat that affects the machine structure (sintering at 14000C tried). A patent application for the FAST machine and tool system has been filed (PG450899GB).
(V). A high-ion current magnetron sputtering procedure developed has achieved a high figure-of-merit of P-type BiSb2Te3 coatings and produced a prototype of thin-film TE module on a flexible Kapton substrate, demonstrating excellent thermoelectric performance which could potentially integrated into solar panels.
(VI). Nickel/GO coating on TE blocks (FS2N and FS2P), plated using a cost-effective pen-brush-plating technique, exhibits good adhesion, lower contact resistance, and enhanced oxidation resistance. This method can reduce the cost by more than 30% compared to other techniques like PVD.
(VII). A well adherent Cr(5-10%)Si coating deposited via PVD has also been achieved, which can protect TE blocks (MgSiSn, hafnium free half-Heusler alloys: NiFeTiSb/ZrTiNiSnSb) from high-temperature oxidation and severe thermal shock degradation, which would ensure reliable operation and extend their service life by at least two-folds.
(VIII). High-energy ball milling that is used for powder recycling has been optimised for the selected materials, leading to the improved recycling efficiency and material recovery, as well as high quality powder recycled. The strategy for establishing waste streams from the whole process/value chains relating to the development of energy harvesting products to be reused and refurbished has also been established and tested.
(IX). A new vibration energy harvesting device multiplying the power generated by a factor of between 2 and 7 (4.5 on average) between 35 and 60 Hz, compared to the standard technique, has been developed, and a sensor based on piezoelectric technology for detecting an acceleration threshold during a defined duration - an energy-autonomous sensor, self-powered, has also been developed.
(X). Smart hybrid PV/TEG systems for land and water uses have been developed and successfully field-tested. The implementation of sensors and IoT has made it possible to use them as systems to support marine navigation and building monitoring, as well as to optimize the systems themselves. An increase in energy output of 20 to 30% by such systems has been demonstrated.
(XI). Energy harvesters have been successfully integrated into a hybrid vehicle through newly designing/improving mechanical, electrical and electronic systems/devices. Real-world testing in various extreme environments has been conducted, and a 7% increase in overall efficiency has been demonstrated.
Overall, the project has produced 16 key exploitable results (KER), with 32% protected by patents. 44% of KERs are expected to be commercialized within 3 to 5 years. All KERs have been demonstrated to the end-users/stakeholders/general public, either through several high-profile events.
(I). High-quality Nano Lead-free Piezoelectric BCZT with favourable dielectric response, low losses (tan delta), low thermal conductivity. A pilot line has been established, presenting advantages over the solid-state reaction with lower reaction time (10 times smaller, comparing to the current state of the art) and low energy consumption.
(II). The process of Solid-state Mechanochemical Synthesis of Thermoelectric Materials at the pilot industrial scale has been established, and validated for productivity of 10kg per day of powder. Seven different TE materials have been synthesised with this process, Hafnium-free Half Heuslers, Lithium-doped P-type silicide, and Bismuth-doped Magnesium Antimonide.
(III). The world first, double-acting, high-precision FAST-sintering press has been constructed and tested, which enables highly precise force, heating and cooling controls, with a fully automated mode for inert gas supply, die-system transfer, sintering, cooling and chamber door-system management.
(IV). A new FAST-sintering die design has been implemented for high-temperature sintering enabling focusing the high sintering temperature mainly at the sintering areas and hence, reducing the heat that affects the machine structure (sintering at 14000C tried). A patent application for the FAST machine and tool system has been filed (PG450899GB).
(V). A high-ion current magnetron sputtering procedure developed has achieved a high figure-of-merit of P-type BiSb2Te3 coatings and produced a prototype of thin-film TE module on a flexible Kapton substrate, demonstrating excellent thermoelectric performance which could potentially integrated into solar panels.
(VI). Nickel/GO coating on TE blocks (FS2N and FS2P), plated using a cost-effective pen-brush-plating technique, exhibits good adhesion, lower contact resistance, and enhanced oxidation resistance. This method can reduce the cost by more than 30% compared to other techniques like PVD.
(VII). A well adherent Cr(5-10%)Si coating deposited via PVD has also been achieved, which can protect TE blocks (MgSiSn, hafnium free half-Heusler alloys: NiFeTiSb/ZrTiNiSnSb) from high-temperature oxidation and severe thermal shock degradation, which would ensure reliable operation and extend their service life by at least two-folds.
(VIII). High-energy ball milling that is used for powder recycling has been optimised for the selected materials, leading to the improved recycling efficiency and material recovery, as well as high quality powder recycled. The strategy for establishing waste streams from the whole process/value chains relating to the development of energy harvesting products to be reused and refurbished has also been established and tested.
(IX). A new vibration energy harvesting device multiplying the power generated by a factor of between 2 and 7 (4.5 on average) between 35 and 60 Hz, compared to the standard technique, has been developed, and a sensor based on piezoelectric technology for detecting an acceleration threshold during a defined duration - an energy-autonomous sensor, self-powered, has also been developed.
(X). Smart hybrid PV/TEG systems for land and water uses have been developed and successfully field-tested. The implementation of sensors and IoT has made it possible to use them as systems to support marine navigation and building monitoring, as well as to optimize the systems themselves. An increase in energy output of 20 to 30% by such systems has been demonstrated.
(XI). Energy harvesters have been successfully integrated into a hybrid vehicle through newly designing/improving mechanical, electrical and electronic systems/devices. Real-world testing in various extreme environments has been conducted, and a 7% increase in overall efficiency has been demonstrated.
Overall, the project has produced 16 key exploitable results (KER), with 32% protected by patents. 44% of KERs are expected to be commercialized within 3 to 5 years. All KERs have been demonstrated to the end-users/stakeholders/general public, either through several high-profile events.
To date, the newly developed materials, manufacturing processes and equipment, and energy harvesters, have clearly demonstrated the advances beyond the current state of the art.
Technologically, the consortium has demonstrated new material technologies and new energy harvesting device designs towards more reliable, flexible and low-cost applications. These have helped to significantly overcome technological barriers previously identified.
Scientifically, the consortium has made contributions to the new knowledge concerning: (i). fundamentals of the materials synthesis for lead-free Piezoelectric (PE) materials and Hf-free half-heusler alloy Thermoelectric (TE) materials; (ii). the mechanisms of FAST sintering of PE/TE nano-materials and structures; (iii). effects of nano-structured superlattice films, graphene or graphene oxide coating and PVD CrSi/CrSi(O) coatings on the TE module performance and efficiency; and (iv). mechanical-electrical and thermo-electrical dynamics properties of energy harvesting devices. These lead to enhancement to the existing theory in the relevant fields.
Socially and economically, the FAST-SAMRT’s developments have great innovation potential, exampled by its high-quality and low-cost materials, high-efficiency micro-manufacturing processes and novel and robust energy harvesting products. Due to these developments, it is expected that the FAST-SMART’s effort will help to speed up applications of networked wireless sensors nodes in Europe in almost all the sectors and domestic uses. At the same time, they would also lead to significant reduction of greenhouse gas emissions and hazardous wastes, as well as overall manufacturing costs, as demonstrated by the project’s Life-cycle analysis and Life-cycle cost analysis.
Technologically, the consortium has demonstrated new material technologies and new energy harvesting device designs towards more reliable, flexible and low-cost applications. These have helped to significantly overcome technological barriers previously identified.
Scientifically, the consortium has made contributions to the new knowledge concerning: (i). fundamentals of the materials synthesis for lead-free Piezoelectric (PE) materials and Hf-free half-heusler alloy Thermoelectric (TE) materials; (ii). the mechanisms of FAST sintering of PE/TE nano-materials and structures; (iii). effects of nano-structured superlattice films, graphene or graphene oxide coating and PVD CrSi/CrSi(O) coatings on the TE module performance and efficiency; and (iv). mechanical-electrical and thermo-electrical dynamics properties of energy harvesting devices. These lead to enhancement to the existing theory in the relevant fields.
Socially and economically, the FAST-SAMRT’s developments have great innovation potential, exampled by its high-quality and low-cost materials, high-efficiency micro-manufacturing processes and novel and robust energy harvesting products. Due to these developments, it is expected that the FAST-SMART’s effort will help to speed up applications of networked wireless sensors nodes in Europe in almost all the sectors and domestic uses. At the same time, they would also lead to significant reduction of greenhouse gas emissions and hazardous wastes, as well as overall manufacturing costs, as demonstrated by the project’s Life-cycle analysis and Life-cycle cost analysis.