Resolving Li-Ion Battery Electrode Particles Using Rapid Lab-Based X-Ray Nano-Computed Tomography for High-Throughput Quantification

Artificial Layer Construction via Cosolvent Enables Stable Ni-Rich Cathodes for Enhanced Lithium Storage

Ni-rich cathodes have recently gained significant attention as next-generation cathodes for lithium-ion batteries. However, their relatively high oxidative surface should be reduced to control the high surface reactivity because the capacity retention decreases rapidly in the batteries. Herein, a simple and effective method to pretreat LiNi0.8Mn0.1Co0.1O2 (NMC811) particles using a cosolvent for improving the battery performance is reported. Imitating the interfacial reaction in practical cells, an artificial layer is created via a spontaneous redox reaction between the cathode and the organic solvent. The artificial layer comprises metal-organic compounds with reduced transition-metal cations. Benefiting from the artificial layer, the cells deliver high capacity retention at a high current density and better rate capability, which might result from the low and stable interfacial resistance of the modified NMC811 cathode. Our approach can effectively reduce the high oxidative surface of most oxide cathode materials and induce a long cyclic lifespan and high capacity retention in most battery systems.

Applications and Development of X-ray Inspection Techniques in Battery Cell Production

Demand for lithium-ion battery cells (LIB) for electromobility has risen sharply in recent years. In order to continue to serve this growing market, large-scale production capacities require further expansion and the overall effectiveness of processes must be increased. Effectiveness can be significantly optimized through innovative manufacturing technology and by identifying scrap early in the production chain. To enable these two approaches, it is imperative to quantify safety- and function-critical product features in critical manufacturing steps through appropriate measurement techniques. The overview in this paper on quality control in LIB production illustrates the necessity for improved inspection techniques with X-rays to realize a fast, online measurement of inner features in large-scale cell assembly with short cycle times and to visualize inner product-process interactions for the optimization in electrolyte filling. Therefore, two new inspection techniques are presented that contribute to overcoming the aforementioned challenges through the targeted use of X-rays. First, based on the results of previous experiments in which the X-ray beam directions were deliberately varied, a online coordinate measurement of anode-cathode (AC) overhang was developed using a line detector. Second, a new concept and the results of a continuous 2D visualization of the electrolyte filling process are presented, which can be used in the future to optimize this time-critical process step. By using a X-ray-permeable and portable vacuum chamber it is possible to quantify the influence of process parameters on the distribution of the electrolyte in the LIB.

Bridging nano- and microscale X-ray tomography for battery research by leveraging artificial intelligence

X-ray computed tomography (CT) is a non-destructive imaging technique in which contrast originates from the materials' absorption coefficient. The recent development of laboratory nanoscale CT (nano-CT) systems has pushed the spatial resolution for battery material imaging to voxel sizes of 50 nm, a limit previously achievable only with synchrotron facilities. Given the non-destructive nature of CT, in situ and operando studies have emerged as powerful methods to quantify morphological parameters, such as tortuosity factor, porosity, surface area and volume expansion, during battery operation or cycling. Combined with artificial intelligence and machine learning analysis techniques, nano-CT has enabled the development of predictive models to analyse the impact of the electrode microstructure on cell performances or the influence of material heterogeneities on electrochemical responses. In this Review, we discuss the role of X-ray CT and nano-CT experimentation in the battery field, discuss the incorporation of artificial intelligence and machine learning analyses and provide a perspective on how the combination of multiscale CT imaging techniques can expand the development of predictive multiscale battery behavioural models.

In situ multiscale probing of the synthesis of a Ni-rich layered oxide cathode reveals reaction heterogeneity driven by competing kinetic pathways

Nickel-rich layered oxides are envisaged as key near-future cathode materials for high-energy lithium-ion batteries. However, their practical application has been hindered by their inferior cycle stability, which originates from chemo-mechanical failures. Here we probe the solid-state synthesis of LiNi_0.6Co_0.2Mn_0.2O₂ in real time to better understand the structural and/or morphological changes during phase evolution. Multi-length-scale observations-using aberration-corrected transmission electron microscopy, in situ heating transmission electron microscopy and in situ X-ray diffraction-reveal that the overall synthesis is governed by the kinetic competition between the intrinsic thermal decomposition of the precursor at the core and the topotactic lithiation near the interface, which results in spatially heterogeneous intermediates. The thermal decomposition leads to the formation of intergranular voids and intragranular nanopores that are detrimental to cycling stability. Furthermore, we demonstrate that promoting topotactic lithiation during synthesis can mitigate the generation of defective structures and effectively suppress the chemo-mechanical failures.

A 4D x-ray computer microtomography for high-temperature electrochemistry

High-temperature electrochemistry is widely used in many fields. However, real-time observations and an in-depth understanding of the inside evolution of this system from an experimental perspective remain limited because of harsh reaction conditions and multiphysics fields. Here, we tackled this challenge with a high-temperature electrolysis facility developed in-house. This facility permits in situ x-ray computer microtomography (μ-CT) for nondestructive and quantitative three-dimensional (3D) imaging. In an electrorefining system, the μ-CT probed the dynamic evolution of 3D morphology and components of electrodes (4D). Subsequently, this 4D process was visually presented via reconstructed images. The results monitor the efficiency of the process, explore the dynamic mechanisms, and even offer real-time optimization. This 4D analysis platform is notable for in-depth combinations of traditional electrochemistry with digital twin technologies owing to its multiscale visualization and high efficiency of data extraction.

Quantificational 4D Visualization of Industrial Electrodeposition

Electrodeposition is a fundamental technology in modern society and has been widely used in metal plating and extraction, etc. However, extreme reaction conditions, including wide operation temperature ranges and corrosive media (molten salt/oxide systems as a particular example), inhibit direct in situ observation of the electrodeposition process. To visualize the electrode kinetics in such "black box," X-ray tomography is employed to monitor the electrochemical processes and three-dimensional (3D) evolution of morphology. Benefiting from the excellent penetration of X-ray, a non-destructive and non-contact in situ four-dimensional (4D) visualization of Ti deposition is realized. Real-time 3D reconstructed images reveal that the counterintuitive nucleation and growth process of a mesoscale Ti dendrite at both solid and liquid cathodes. According to 3D morphology evolution, unusual mechanism based on synergetic effect of the diffusion of metallic Ti and local field enhancement is achieved utilizing a simulation method based on a finite element method. This approach allows for timely and accurately regulating the electrodeposition process upon in situ monitored parameters. More importantly, the 4D technique upon operando X-ray tomography and numerical simulation can be easily applied to other electrodeposition systems, which will help deeply understand the internal kinetics and the precise optimization of the electrodeposition conditions.