Optimizing CuFeS2 Chalcopyrite Thin Film Synthesis: A Comprehensive Three-Step Approach Using Ball-Milling, Thermal Evaporation, and Sulfurization Applied for Thermoelectric Generation

CuFeS2 (CFS) stands out as a promising narrow band-gap semiconductor for thermoelectric (TE) applications. However, its high lattice thermal conductivity is one of the factors hampering its potential for TE generation. A common strategy for tackling this problem is to produce this material in thin film form. Thus, this study aims to practically understand and optimize the synthesis of CFS 2D materials using a simple three-step approach of ball-milling, thermal evaporation, and sulfurization of the CuFe metallic precursors. The tools for thin film characterization employ X-ray Diffraction (XRD), Scanning Electron Microscopy (SEM), Energy-Dispersive X-ray Spectroscopy (EDXS), and Hall-effect measurements. DFT phase diagrams are also used to understand the energy of formation of the secondary phases present in the film. Here, we highlight that the ball-milling mechanisms, allied with high vacuum and high energy density during evaporation, are essential for the interdiffusion of Cu and Fe during the evaporation process. The film presented a flower-like morphology and p-type semiconducting behavior. A proof-of-concept Thermoelectric Generator (TEG) was designed in an in-plane geometry, showing a power output per unit active area of 114 nW cm−2 (ΔT = 180 °C), comparable to other Cu-based materials, thus demonstrating the feasibility of this method of synthesis for TE applications.