Enhancement of Power Factor and Mechanical Properties in Low Cost Mg₂Si_1–xSn_x Employing a Composite Approach

High cost, toxicity, and thermal instability issues curtail the usage of thermoelectric power generators (TEGs) for waste heat recovery applications. Mg2Si1–xSnx based thermoelectric material is a proven low cost, nontoxic, and earth crust abundant material for mid-temperature device applications. Still, its thermal stability and mechanical properties remain challenging and unascertained. This work reports a facile and simple production of Mg2Si1–xSnx material employing a composite approach using an in situ plasma-assisted reaction sintering process. The enhanced thermoelectric properties associated with a remarkable hardness value of ≃5.2 GPa and high fracture strength of ≃2.17 MPa√m were realized in plasma-assisted reactive sintered Mg2Si1–xSnx material, using suitable doping and reinforcement additions. The synthesized composite material improves the mechanical robustness and superior thermoelectric performance, which is a prerequisite for ensuring the commercial viability of Mg2Si1–xSnx based materials.