Optimization of Silicon–Germanium thermoelectric generator system used in exhaust systems of internal combustion engines

• Optimized SiGe TEG boosts power and efficiency under high heat flux. • Output power improved by 316 %, efficiency by 257 % at 800 kW/m². • Best design: A = 1.36 mm², L = 4 mm, t p = 0.58 mm. • Strip thickness has minimal effect on TEG performance. The performance of thermoelectric generators must be improved because of recent evidence of decreased efficiency. Its size and the copper strip's thickness might be changed to achieve this. Finding the ideal P-N leg dimensions while taking into consideration all potential interactions under high operational heat fluxes is the aim of the current effort. In addition to using the single objective optimization approach, a comprehensive TEG model is developed to do this. Based on the simulation, the main performance parameters, hot side temperature ( T h ) , voltage (V), output power (P), and conversion efficiency (η) are evaluated and compared to the traditional TEG system. The findings showed that the leg length (L) and cross-sectional area (A) significantly influence the performance metrics. However, there is minimal variation in the conducting plate's thickness ( t p ) . For example, a P-N combined with a leg size of 4 mm generates 0.013 W and 0107 W for various heat fluxes of 20 kW/m 2 and 800 kW/m 2 , respectively. Furthermore, the matching efficiencies are 0.2 % and 4.8 %. According to genetic algorithm results, the optimum values for t p , L and A are 0.58487 mm, 3.9987 mm, and 1.357 mm 2 , respectively. With a heat flux of 800 kW/m 2 , the suggested design may increase TEG-generated performance parameters up to 257 % in hot side temperature, 253 % in voltage, 316 % in output power, and 257 % in conversion efficiency, respectively, compared with the traditional system.