Mechanically durable thermoelectric power generation module made of Ni-based alloy as a reference for reliable testing

[Display omitted] •We develop a thermoelectric module made of Ni-based alloys as a standard reference.•Ni90Cr10 and Cu55Ni45 are used in p-type and n-type legs, respectively.•Module developed in this study is chemically, thermally and mechanically stable.•Power generation characteristics are reproducible in repeated and continuous tests. In this study, we fabricated a thermoelectric module made of Ni-based alloy as standard reference for use in cross-checking the power generation characteristics of module testing systems. The module was fabricated with eight pairs of legs made from mechanically durable p-type Ni90Cr10 (chromel) and n-type Cu55Ni45 (constantan). To increase thermal resistance of the module, holes were made in the p- and n-type Ni-based alloys, thereby reducing the effective density of the legs by ~57.1%. As a result, a thermal resistance of 6.16 K W−1 was obtained at a hot-side temperature (Th) of 773 K and cold-side temperature (Tc) of 323 K. A maximum electrical power (Pmax) of ~0.39 W and maximum conversion efficiency (ηmax) of ~0.53% were obtained for the module with holes at Th of 773 K and Tc of 323 K. We confirmed the reproducibility of power generation characteristics, including the open circuit voltage (Voc), internal resistance (Rin), Pmax, output heat flow (Qout), and ηmax of the module, through 12 repeated tests and ~120 h of continuous tests at Th of 773 K and Tc of 323 K. The variation of Voc, Rin, Pmax, Qout, and ηmax is with standard deviation less than 1% from their mean values.