Aluminum foil negative electrodes with multiphase microstructure for all-solid-state Li-ion batteries

A Porous Li-Al Alloy Anode toward High-Performance Sulfide-Based All-Solid-State Lithium Batteries

Compared to lithium (Li) anode, the alloy/Li-alloy anodes show more compatible with sulfide solid electrolytes (SSEs), and are promising candidates for practical SSE-based all-solid-state Li batteries (ASSLBs). In this work, a porous Li-Al alloy (LiAl-p) anode is crafted using a straightforward mechanical pressing method. Various characterizations confirm the porous nature of such anode, as well as rich oxygen species on its surface. To the best knowledge, such LiAl-p anode demonstrates the best room temperature cell performance in comparison with reported Li and alloy/Li-alloy anodes in SSE-based ASSLBs. For example, the LiAl-p symmetric cells deliver a record critical current density of 6.0 mA cm-2 and an ultralong cycling of 5000 h; the LiAl-p|LiNi0.8Co0.1Mn0.1O2 full cells achieve a high areal capacity of 11.9 mAh cm-2 and excellent durability of 1800 cycles. Further in situ and ex situ experiments reveal that the porous structure can accommodate volume changes of LiAl-p and ensure its integrity during cycling; and moreover, a robust Li inorganics-rich solid electrolyte interphase can be formed originated from the reaction between SSE and surface oxygen species of LiAl-p. This study offers inspiration for designing high-performance alloy anodes by focusing on designing special architecture to alleviate volume change and constructing stable interphase.

Cellulose-Encapsulated Composite Electrolyte Design: Toward Chemically and Mechanically Enhanced Solid-Sodium Batteries

Sulfide- and halide-based ceramic ionic conductors exhibit comparable ionic conductivity with liquid electrolytes and are candidates for high-energy- and high-power-density all-solid-state batteries. These materials, however, are inherently brittle, making them unfavorable for applications. Here, we report a mechanically enhanced composite Na+ conductor that contains 92.5 wt % of sodium thioantimonate (Na3SbS4, NSS) and 7.5 wt % of sodium carboxymethyl cellulose (CMC); the latter serves as the binder and an electrochemically inert encapsulation layer. The ceramic and binder constituents were integrated at the particle level, providing ceramic NSS-level Na+ conductivity in the NSS-CMC composite. The more than 5-fold decrease of electrolyte thickness obtained in NSS-CMC composite provided a 5-fold increase in Na+ conductance compared to NSS ceramic pellets. As a result of the CMC encapsulation, this NSS-CMC composite shows increased moisture resistivity and electrochemical stability, which significantly promotes the cycling performance of NSS-based solid-state batteries. This work demonstrates a well-controlled, orthogonal process of ceramic-rich, composite electrolyte processing: independent streams for ceramic particle formation along with binder encapsulation in a solvent-assisted environment. This work also provides insights into the interplay among the solvent, the polymeric binder, and the ceramic particles in composite electrolyte synthesis and implies the critical importance of identifying the appropriate solvent/binder system for precise control of this complicated process.

Electrochemical behavior of elemental alloy anodes in solid-state batteries

Lithium alloy anodes in the form of dense foils offer significant potential advantages over lithium metal and particulate alloy anodes for solid-state batteries (SSBs). However, the reaction and degradation mechanisms of dense alloy anodes remain largely unexplored. Here, we investigate the electrochemical lithiation/delithiation behavior of 12 elemental alloy anodes in SSBs with Li6PS5Cl solid-state electrolyte (SSE), enabling direct behavioral comparisons. The materials show highly divergent first-cycle Coulombic efficiency, ranging from 99.3% for indium to ∼20% for antimony. Through microstructural imaging and electrochemical testing, we identify lithium trapping within the foil during delithiation as the principal reason for low Coulombic efficiency in most materials. The exceptional Coulombic efficiency of indium is found to be due to unique delithiation reaction front morphology evolution in which the high-diffusivity LiIn phase remains at the SSE interface. This study links composition to reaction behavior for alloy anodes and thus provides guidance toward better SSBs.

Enhancing Durability and Capacity Retention of Ultrafine-Grained Aluminum Foil Anodes in Lithium-Ion Batteries

In this study, we present our successful fabrication of commercial-grade pure aluminum anode foil (99.5%, 2NAl) with an ultrafine-grained (UFG) microstructure and high hardness, achieved through cold rolling. Under identical rolling conditions, a coarse-grained microstructure with a low hardness was attained from the high-purity Al foil (99.99%, 4NAl). The UFG 2NAl foil exhibited enhanced lithium-ion diffusivity and reduced nucleation and activation overpotentials for forming the β-LiAl phase compared to the 4NAl foil. The high-density grain boundaries in the UFG 2NAl foil facilitated the rapid formation of a uniform β-LiAl phase layer on its surface, thereby mitigating mechanical damage within the β-LiAl phase layer caused by volume changes during the lithiation and delithiation processes. The high hardness of the UFG 2NAl sample effectively prevented macroscopic plastic deformation during cycling, thus preserving the integrity of the β-LiAl phase layer and inhibiting the formation of cracks within the unreacted Al matrix. The collective advantages of reduced overpotential, enhanced Li-ion diffusivity, and high resistance to mechanical damage and plastic deformation in UFG 2NAl contribute to its superior durability and capacity retention compared to the high-purity Al in electrochemical cycling.

Computational approach inspired advancements of solid-state electrolytes for lithium secondary batteries: from first-principles to machine learning

The increasing demand for high-security, high-performance, and low-cost energy storage systems (EESs) driven by the adoption of renewable energy is gradually surpassing the capabilities of commercial lithium-ion batteries (LIBs). Solid-state electrolytes (SSEs), including inorganics, polymers, and composites, have emerged as promising candidates for next-generation all-solid-state batteries (ASSBs). ASSBs offer higher theoretical energy densities, improved safety, and extended cyclic stability, making them increasingly popular in academia and industry. However, the commercialization of ASSBs still faces significant challenges, such as unsatisfactory interfacial resistance and rapid dendrite growth. To overcome these problems, a thorough understanding of the complex chemical-electrochemical-mechanical interactions of SSE materials is essential. Recently, computational methods have played a vital role in revealing the fundamental mechanisms associated with SSEs and accelerating their development, ranging from atomistic first-principles calculations, molecular dynamic simulations, multiphysics modeling, to machine learning approaches. These methods enable the prediction of intrinsic properties and interfacial stability, investigation of material degradation, and exploration of topological design, among other factors. In this comprehensive review, we provide an overview of different numerical methods used in SSE research. We discuss the current state of knowledge in numerical auxiliary approaches, with a particular focus on machine learning-enabled methods, for the understanding of multiphysics-couplings of SSEs at various spatial and time scales. Additionally, we highlight insights and prospects for SSE advancements. This review serves as a valuable resource for researchers and industry professionals working with energy storage systems and computational modeling and offers perspectives on the future directions of SSE development.

The interface engineering and structure design of an alloying-type metal foil anode for lithium ion batteries: a review

An alloying-type metal foil serves as an integrated anode that is distinct from the prevalent powder-casting production of lithium ion batteries (LIBs) and emerging lithium metal batteries (LMBs), and also its energy density and processing technology can be profoundly developed. However, besides their apparent intriguing advantages of a high specific capacity, electrical conductivity, and the ease of formation, metal foil anodes suffer from slow lithiation kinetics, a trade-off between specific capacity and cycle life, and a low initial Coulombic efficiency (ICE) owing to their multi-scaled structural geometry, huge volume change, and induced interfacial issues during the alloying process. In this review, we attempt to present a comprehensive overview on the recent research progress with respect to alloying-type metal foil anodes toward high-energy-density and low-cost LIBs. The failure mechanism of metal foil anodes during lithiation/delithiation and existing challenges are also summarized. Subsequently, the structural design and interface engineering strategies that have witnessed significant achievements are highlighted, which can promote the practical development of LIBs, including artificial SEI, alloying, structural design, and grain refinement. Furthermore, scientific perspectives are proposed to further improve the overall performance and decouple the complex mechanisms in terms of interdisciplinary fields of electrochemistry, metallic materials science, mechanics, and interfacial science, demonstrating that metal foil anode-based LIBs require more research efforts.

A Multiscale, Dynamic Elucidation of Li Solubility in the Alloy and Metallic Plating Process

Li-containing alloys and metallic deposits offer substantial Li+ storage capacities as alternative anodes to commercial graphite. However, the thermodynamically in sequence, yet kinetically competitive mechanism between Li solubility in the solid solution and intermediate alloy-induced Li deposition remains debated, particularly across the multiple scales. The elucidation of the mechanism is rather challenging due to the dynamic alloy evolution upon the non-equilibrium, transient lithiation processes under coupled physical fields. Here, influential factors governing Li solubility in the Li-Zn alloy are comprehensively investigated as a demonstrative model, spanning from the bulk electrolyte solution to the ion diffusion within the electrode. Through real-time phase tracking and spatial distribution analysis of intermediate alloy/Li metallic species at varied temperatures, current densities and particle sizes, the driving force of Li solubility and metallic plating along the Li migration pathway are probed in-depth. This study investigates the correlation between kinetics (pronounced concentration polarization, miscibility gap in lattice grains) and rate-limiting interfacial charge transfer thermodynamics in dedicating the Li diffusion into the solid solution. Additionally, the lithiophilic alloy sites with the balanced diffusion barrier and Li adsorption energy are explored to favor the homogeneous metal plating, which provides new insights for the rational innovation of high-capacity alloy/metallic anodes.