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Electronic structure of Zr-Ni-Sn systems: role of clustering and nanostructures in Half-Heusler and Heusler limits

Half-Heusler and Heusler compounds have been of great interest for several decades for thermoelectric, magnetic, half-metallic and many other interesting properties. Among these systems, Zr-Ni-Sn compounds are interesting thermoelectrics which can go from semiconducting half-Heusler (HH) limit, ZrNiSn, to metallic Heusler (FH) limit, ZrNi$_2$Sn. Recently Makogo et al. [J. Am. Chem. Soc. 133, 18843 (2011)] found that dramatic improvement in the thermoelectric power factor of HH can be achieved by putting excess Ni into the system. This was attributed to an energy filtering mechanism due to the formation of FH nanostructures in the HH matrix. Using density functional theory we have investigated clustering and nanostructure formation in HH$_{1-x}$FH$_x$ systems near the HH and FH ends and found that excess Ni atoms in HH tend to stay close to each other and form nanoclusters of FH. On the other hand, there is competing interaction between Ni-vacancies in FH which prevent them from forming HH nano clusters. Effects of nano inclusions on the electronic structure at both HH and FH ends will be discussed.