Two types of p-n joined Si0.8Ge0.2 thermoelectric elements were fabricated by pulse-current sintering of the corresponding gas-atomized powders. The first type of thermoelectric couple was obtained by making a slit between the p- and n-type thermoelectric elements after being directly joined by sintering. The second type of couple had an alumina layer inserted in the slit to strengthen the couple. The thermoelements were firmly connected in both cases without any crack. No change in the alumina layer was noticed after sintering, which may be attributed to the very short sintering time. The electrical output of these couples was strongly dependent on their dimensions and configurations. The couples, made of elements 26 mm long and 2.5 mm wide joined over 2 mm, produce the useful electrical outputs of 46 and 49 mW without and with an alumina layer at 1273 K, respectively. (c) 2005 The Electrochemical Society.