Developing inexpensive and rapid fabrication methods for high efficiency thermoelectric alloys is a crucial challenge for the thermoelectric industry, especially for energy conversion applications. Here, we fabricated large amounts of p-type Cu_0.07Bi_0.5Sb_1.5Te₃ alloys, using water atomization to control its microstructure and improve thermoelectric performance by optimizing its initial powder size. All the water atomized powders were sieved with different aperture sizes, of 32–75 μm, 75–125 μm, 125–200 μm, and <200 μm, and subsequently consolidated using hot pressing at 490 °C. The grain sizes were found to increase with increasing powder particle size, which also increased carrier mobility due to improved carrier transport. The maximum electrical conductivity of 1457.33 Ω⁻¹ cm⁻¹ was obtained for the 125–200 μm samples due to their large grain sizes and subsequent high mobility. The Seebeck coefficient slightly increased with decreasing particle size due to scattering of carriers at fine grain boundaries. The higher power factor values of 4.20, 4.22 × 10⁻³ W/mk² were, respectively, obtained for large powder specimens, such as 125–200 μm and 75–125 μm, due to their higher electrical conductivity. In addition, thermal conductivity increased with increasing particle size due to the improvement in carriers and phonons transport. The 75–125 μm powder specimen exhibited a relatively high thermoelectric figure of merit, ZT of 1.257 due to this higher electric conductivity.

Bismuth-Telluride-based compounds are unique materials for thermoelectric cooling applications. Because Bi₂Te₃ is a narrow gap semiconductor, the bipolar diffusion effect is a critical issue to enhance thermoelectric performance. Here, we report the significant reduction of thermal conductivity by decreasing lattice and bipolar thermal conductivity in extrinsic phase mixing of MgO and VO₂ nanoparticles in Bi_0.5Sb_1.5Te₃ (BST) bulk matrix. When we separate the thermal conductivity by electronic ${\kappa }_{el}$, lattice ${\kappa }_{lat}$, and bipolar ${\kappa }_{bi}$ thermal conductivities, all the contributions in thermal conductivities are decreased with increasing the concentration of oxide particle distribution, indicating the effective phonon scattering with an asymmetric scattering of carriers. The reduction of thermal conductivity affects the improvement of the ZT values. Even though significant carrier filtering effect is not observed in the oxide bulk composites due to micro-meter size agglomeration of particles, the interface between oxide and bulk matrix scatters carriers giving rise to the increase of the Seebeck coefficient and electrical resistivity. Therefore, we suggest the extrinsic phase mixing of nanoparticles decreases lattice and bipolar thermal conductivity, resulting in the enhancement of thermoelectric performance over a wide temperature range.