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

Defect Chemistry in High-Voltage Cathode Materials for Lithium-Ion Batteries

High-voltage cathodes (HVCs) have emerged as a paramount role for the next-generation high-energy-density lithium-ion batteries (LIBs). However, the pursuit of HVCs comes with inherent challenges related to defective structures, which significantly impact the electrochemical performance of LIBs. The current obstacle lies in the lack of a comprehensive understanding of defects and their precise effects. This perspective aims to provide insights into defect chemistry for governing HVCs. The classifications, formation mechanisms, and evolution of defects are outlined to explore the intricate relationship between defects and electrochemical behavior. The pressing need for cutting-edge characterization techniques that comprehensively investigate defects across various temporal and spatial scales is emphasized. Building on these fundamental understandings, engineering strategies such as composition tailoring, morphology design, interface modification, and structural control to mitigate or utilize defects are thoroughly discussed for enhanced HVCs performance. These insights are expected to provide vital guidelines for developing high-performance HVCs for next-generation high-energy lithium-ion batteries.

Surface Catalytic Repair for the Efficient Regeneration of Spent Layered Oxide Cathodes

Direct recycling is considered to be the next-generation recycling technology for spent lithium-ion batteries due to its potential economic benefits and environmental friendliness. For the spent layered oxide cathode materials, an irreversible phase transition to a rock-salt structure near the particle surface impedes the reintercalation of lithium ions, thereby hindering the lithium compensation process from fully restoring composition defects and repairing failed structures. We introduced a transition-metal hydroxide precursor, utilizing its surface catalytic activity produced during annealing to convert the rock-salt structure into a layered structure that provides fast migration pathways for lithium ions. The material repair and synthesis processes share the same heating program, enabling the spent cathode and added precursor to undergo a topological transformation to form the targeted layered oxide. This regenerated material exhibits a performance superior to that of commercial cathodes and maintains 88.4% of its initial capacity after 1000 cycles in a 1.3 Ah pouch cell. Techno-economic analysis highlights the environmental and economic advantages of surface catalytic repair over pyrometallurgical and hydrometallurgical methods, indicating its potential for practical application.

Unveiling crystal orientation-dependent interface property in composite cathodes for solid-state batteries by in situ microscopic probe

A critical bottleneck toward all-solid-state batteries lies in how the solid(electrode)-solid(electrolyte) interface is fabricated and maintained over repeated cycles. Conventional composite cathodes, with crystallographically distinct electrode/electrolyte interfaces of random particles, create complexities with varying (electro)chemical compatibilities. To address this, we employ an epitaxial model system where the crystal orientations of cathode and solid electrolyte are precisely controlled, and probe the interfaces in real-time during co-sintering by in situ electron microscopy. The interfacial reaction is highly dependent on crystal orientation/alignment, especially the availability of open ion channels. Interfaces bearing open ion paths of NCM are more susceptible to interdiffusion, but stabilize with the early formed passivation layer. Conversely, interfaces with closed ion pathway exhibit stability at intermediate temperatures, but deteriorate rapidly at high temperature due to oxygen evolution, increasing interfacial resistance. The elucidation of these distinct interfacial behaviors emphasizes the need for decoupling collective interfacial properties to enable rational design in solid-state batteries.

Microstrain screening towards defect-less layered transition metal oxide cathodes

Microstrain and the associated surface-to-bulk propagation of structural defects are known to be major roadblocks to developing high-energy and long-life batteries. However, the origin and effects of microstrain during the synthesis of battery materials remain largely unknown. Here we perform microstrain screening during real-time and realistic synthesis of sodium layered oxide cathodes. Evidence gathered from multiscale in situ synchrotron X-ray diffraction and microscopy characterization collectively reveals that the spatial distribution of transition metals within individual precursor particles strongly governs the nanoscale phase transformation, local charge heterogeneity and accumulation of microstrain during synthesis. This unexpected dominance of transition metals results in a counterintuitive outward propagation of defect nucleation and growth. These insights direct a more rational synthesis route to reduce the microstrain and crystallographic defects within the bulk lattice, leading to significantly improved structural stability. The present work on microstrain screening represents a critical step towards synthesis-by-design of defect-less battery materials.

Spheroidization: The Impact of Precursor Morphology on Solid-State Lithiation Process for High-Quality Ultrahigh-Nickel Oxide Cathodes

Layered oxides with ultrahigh nickel content are considered promising high energy cathode materials. However, their cycle stability is constrained by a series of heterogeneous structural transformations during the complex solid-state lithiation process. By in-depth investigation into the solid-state lithiation process of LiNi0.92Co0.04Mn0.04O2, it is found that the protruded parts on the surface of precursor particles tend to be surrounded by locally excessive LiOH, which promotes the formation of a rigid and denseR 3 - m ${{\rm { R}}\mathrel{\mathop{{\rm { 3}}}\limits^{{\rm -}}}{\rm { m}}}$ shell during the early stage of lithiation process. The shell will hinder the diffusion of lithium and topotactic lithiation within the particles, culminating in spatially heterogeneous intermediates that can impair the electrochemical properties of the cathode material. The spheroidization of the precursor can enhance uniformity in structural evolution during solid-phase lithiation. Ultrahigh nickel cathodes derived from spherical precursors demonstrate high initial discharge specific capacity (234.2 mAh g-1, in the range of 2.7-4.3 V) and capacity retention (89.3 % after 200 cycles), significantly superior to the non-spherical samples. This study not only sheds light on the intricate relationship between precursor shape and structural transformation but also introduces a novel strategy for enhancing cathode performance through precursor spheroidization.

Reviving Fatigue Surface for Solid-State Upcycling of Highly Degraded Polycrystalline LiNi1-x-yCoxMnyO2 Cathodes

The ongoing tide of spent lithium-ion batteries (LIBs) urgently calls for high-value output in efficient recycling. Recently, direct regeneration has emerged as a novel recycling strategy but fails to repair the irreversible morphology and structure damage of the highly degraded polycrystalline layered oxide materials. Here, this work carries out a solid-state upcycling study for the severely cracked LiNi1-x-yCoxMnyO2 cathodes. The specific single-crystallization process during calcination is investigated and the surface rock salt phase is recognized as the intrinsic obstacle to the crystal growth of the degraded cathodes due to sluggish diffusion in the heterogeneous grain boundary. Accordingly, this work revives the fatigue rock salt phase by restoring a layered surface and successfully reshapes severely broken cathodes into the high-performance single-crystalline particles. Benefiting from morphological and structural integrity, the upcycled single-crystalline cathode materials exhibit an enhanced capacity retention rate of 93.5% after 150 cycles at 1C compared with 61.7% of the regenerated polycrystalline materials. The performance is also beyond that of the commercial cathodes even under a high cut-off voltage (4.5 V) or high operating temperature (45 °C). This work provides scientific insights for the upcycling of the highly degraded cathodes in spent LIBs.

Probing Particle-Carbon/Binder Degradation Behavior in Fatigued Layered Cathode Materials through Machine Learning Aided Diffraction Tomography

Understanding how reaction heterogeneity impacts cathode materials during Li-ion battery (LIB) electrochemical cycling is pivotal for unraveling their electrochemical performance. Yet, experimentally verifying these reactions has proven to be a challenge. To address this, we employed scanning μ-XRD computed tomography to scrutinize Ni-rich layered LiNi0.6Co0.2Mn0.2O2 (NCM622) and Li-rich layered Li[Li0.2Ni0.2Mn0.6]O2 (LLNMO). By harnessing machine learning (ML) techniques, we scrutinized an extensive dataset of μ-XRD patterns, about 100,000 patterns per slice, to unveil the spatial distribution of crystalline structure and microstrain. Our experimental findings unequivocally reveal the distinct behavior of these materials. NCM622 exhibits structural degradation and lattice strain intricately linked to the size of secondary particles. Smaller particles and the surface of larger particles in contact with the carbon/binder matrix experience intensified structural fatigue after long-term cycling. Conversely, both the surface and bulk of LLNMO particles endure severe strain-induced structural degradation during high-voltage cycling, resulting in significant voltage decay and capacity fade. This work holds the potential to fine-tune the microstructure of advanced layered materials and manipulate composite electrode construction in order to enhance the performance of LIBs and beyond.

Enhancing the Structural Stability and Electrochemical Performance of High-Nickel Cathode Materials through Ti Doping with an Exothermic Non-oxide Precursor

The foreseeable global cobalt (Co) crisis has driven the demand for cathode materials with less Co dependence, where high-nickel layered oxides are a promising solution due to their high energy density and low cost. However, these materials suffer from poor cycling stability and rapid voltage decay due to lattice displacement and nanostrain accumulation. Here, we introduced an exothermic TiN dopant via a scalable coating method to stabilize LiNi0.917Co0.056Mn0.026O2 (NCM92) materials. The exothermic reaction of TiN conversion generates extra heat during the calcination process on the cathode surface, promotes the lithiation process, and tunes the morphology of the cathode material, resulting in compact and conformal smaller particle sizes to provide better particle integration and lithium diffusion coefficient. Moreover, the Ti dopant substitutes the Ni3+ site to generate stronger Ti-O bonding, leading to higher structural stability and extended cycle life. The Ti-doped NCM (NCM92_TiN) shows a remarkable cycling stability of maintaining 80% capacity retention for 400 cycles, while bare NCM92 can only reach 88 cycles. Furthermore, the NCM92_TiN cathodes demonstrate an enhanced rate capability and achieve a discharge capacity of over 168 mAh g-1 at 5C.

Side Reactions/Changes in Lithium-Ion Batteries: Mechanisms and Strategies for Creating Safer and Better Batteries

Lithium-ion batteries (LIBs), in which lithium ions function as charge carriers, are considered the most competitive energy storage devices due to their high energy and power density. However, battery materials, especially with high capacity undergo side reactions and changes that result in capacity decay and safety issues. A deep understanding of the reactions that cause changes in the battery's internal components and the mechanisms of those reactions is needed to build safer and better batteries. This review focuses on the processes of battery failures, with voltage and temperature as the underlying factors. Voltage-induced failures result from anode interfacial reactions, current collector corrosion, cathode interfacial reactions, overcharge, and over-discharge, while temperature-induced failure mechanisms include SEI decomposition, separator damage, and interfacial reactions between electrodes and electrolytes. The review also presents protective strategies for controlling these reactions. As a result, the reader is offered a comprehensive overview of the safety features and failure mechanisms of various LIB components.

Approaching Ultimate Synthesis Reaction Rate of Ni-Rich Layered Cathodes for Lithium-Ion Batteries

Nickel-rich layered oxide LiNixCoyMnzO2 (NCM, x + y + z = 1) is the most promising cathode material for high-energy lithium-ion batteries. However, conventional synthesis methods are limited by the slow heating rate, sluggish reaction dynamics, high energy consumption, and long reaction time. To overcome these challenges, we first employed a high-temperature shock (HTS) strategy for fast synthesis of the NCM, and the approaching ultimate reaction rate of solid phase transition is deeply investigated for the first time. In the HTS process, ultrafast average reaction rate of phase transition from Ni0.6Co0.2Mn0.2(OH)2 to Li- containing oxides is 66.7 (% s-1), that is, taking only 1.5 s. An ultrahigh heating rate leads to fast reaction kinetics, which induces the rapid phase transition of NCM cathodes. The HTS-synthesized nickel-rich layered oxides perform good cycling performances (94% for NCM523, 94% for NCM622, and 80% for NCM811 after 200 cycles at 4.3 V). These findings might also assist to pave the way for preparing effectively Ni-rich layered oxides for lithium-ion batteries.

Microstructures of layered Ni-rich cathodes for lithium-ion batteries

Millions of electric vehicles (EVs) on the road are powered by lithium-ion batteries (LIBs) based on nickel-rich layered oxide (NRLO) cathodes, and they suffer from a limited driving range and safety concerns. Increasing the Ni content is a key way to boost the energy densities of LIBs and alleviate the EV range anxiety, which are, however, compromised by the rapid performance fading. One unique challenge lies in the worsening of the microstructural stability with a rising Ni-content in the cathode. In this review, we focus on the latest advances in the understanding of NLRO microstructures, particularly the microstructural degradation mechanisms, state-of-the-art stabilization strategies, and advanced characterization methods. We first elaborate on the fundamental mechanisms underlying the microstructural failures of NRLOs, including anisotropic lattice evolution, microcracking, and surface degradation, as a result of which other degradation processes, such as electrolyte decomposition and transition metal dissolution, can be severely aggravated. Afterwards, we discuss representative stabilization strategies, including the surface treatment and construction of radial concentration gradients in polycrystalline secondary particles, the fabrication of rod-shaped primary particles, and the development of single-crystal NRLO cathodes. We then introduce emerging microstructural characterization techniques, especially for identification of the particle orientation, dynamic changes, and elemental distributions in NRLO microstructures. Finally, we provide perspectives on the remaining challenges and opportunities for the development of stable NRLO cathodes for the zero-carbon future.

Comparison Study of a Thermal-Driven Microstructure in a High-Ni Cathode for Lithium-Ion Batteries: Critical Calcination Temperature for Polycrystalline and Single-Crystalline Design

High-Ni layered oxide cathodes are promising candidates for lithium-ion batteries due to their high energy density. However, their cycle stability is compromised by the poor mechanical durability of the particle microstructure. In this study, we investigate the impact of the calcination temperature on microstructural changes, including primary particle growth and pore evolution, using LiNi0.88Mn0.08Co0.04O2 (N884), with an emphasis on the critical calcination temperature for polycrystalline and single-crystal designs in high-Ni cathodes. As the calcination temperature increases, the primary particles undergo a rectangular growth pattern while the pore population decreases. Beyond a certain critical temperature (in this case, 850 °C), a sudden increase in primary particle size and a simultaneous rapid reduction in the pore population are observed. This sudden microstructure evolution leads to poor cycle retention in N884. In contrast, single-crystal particles, free of grain boundaries, synthesized at this critical temperature exhibit superior cycle retention, underscoring the significance of microstructural design over crystalline quality for achieving long-term cyclability. Our study sheds light on the interplay between calcination temperature and microstructural evolution, proposing the critical temperature as a key criterion for single-crystal synthesis.

The Chemistry of Spinel Ferrite Nanoparticle Nucleation, Crystallization, and Growth

The nucleation, crystallization, and growth mechanisms of MnFe2O4, CoFe2O4, NiFe2O4, and ZnFe2O4 nanocrystallites prepared from coprecipitated transition metal (TM) hydroxide precursors treated at sub-, near-, and supercritical hydrothermal conditions have been studied by in situ X-ray total scattering (TS) with pair distribution function (PDF) analysis, and in situ synchrotron powder X-ray diffraction (PXRD) with Rietveld analysis. The in situ TS experiments were carried out on 0.6 M TM hydroxide precursors prepared from aqueous metal chloride solutions using 24.5% NH4OH as the precipitating base. The PDF analysis reveals equivalent nucleation processes for the four spinel ferrite compounds under the studied hydrothermal conditions, where the TMs form edge-sharing octahedrally coordinated hydroxide units (monomers/dimers and in some cases trimers) in the aqueous precursor, which upon hydrothermal treatment nucleate through linking by tetrahedrally coordinated TMs. The in situ PXRD experiments were carried out on 1.2 M TM hydroxide precursors prepared from aqueous metal nitrate solutions using 16 M NaOH as the precipitating base. The crystallization and growth of the nanocrystallites were found to progress via different processes depending on the specific TMs and synthesis temperatures. The PXRD data show that MnFe2O4 and CoFe2O4 nanocrystallites rapidly grow (typically <1 min) to equilibrium sizes of 20-25 nm and 10-12 nm, respectively, regardless of applied temperature in the 170-420 °C range, indicating limited possibility of targeted size control. However, varying the reaction time (0-30 min) and temperature (150-400 °C) allows different sizes to be obtained for NiFe2O4 (3-30 nm) and ZnFe2O4 (3-12 nm) nanocrystallites. The mechanisms controlling the crystallization and growth (nucleation, growth by diffusion, Ostwald ripening, etc.) were examined by qualitative analysis of the evolution in refined scale factor (proportional to extent of crystallization) and mean crystallite volume (proportional to extent of growth). Interestingly, lower kinetic barriers are observed for the formation of the mixed spinels (MnFe2O4 and CoFe2O4) compared to the inverse (NiFe2O4) and normal (ZnFe2O4) spinel structured compounds, suggesting that the energy barrier for formation may be lowered when the TMs have no site preference.

Stabilizing the Deep Sodiation Process in Layered Sodium Manganese Cathodes by Anchoring Boron Ions

Advanced high-energy-density sodium-ion batteries (SIBs) are inseparable from cathode materials with high specific capacities. Layered manganese-rich oxides (NaxMnO2, 0.6 ≤ x ≤1) are promising cathode materials owing to their ease of intercalation and extraction of a considerable amount of sodium ions. However, lattice interactions, especially electrostatic repulsive forces and anisotropic stresses, are usually caused by deep desodiatin/sodiation process, resulting in intragranular cracks and capacity degradation in SIBs. Here, boron ions are introduced into the layered structure to build up B─O─Mn bonds. The regulated electronic structure in Na0.637B0.038MnO2 (B-NMO) materials inhibits the deformation of MnO6 octahedra, which finally achieves a gentle structural transition during the deep sodiation process. B-NMO electrode exhibits a high capacity (141 mAh g-1) at 1 C with a capacity retention of 81% after 100 cycles. Therefore, anchoring boron to manganese-rich materials inhibits the detrimental structural evolution of deep sodiation and can be used to obtain excellent cathode materials for SIBs.

Why the Synthesis Affects Performance of Layered Transition Metal Oxide Cathode Materials for Li-Ion Batteries

The limited cyclability of high-specific-energy layered transition metal oxide (LiTMO2) cathode materials poses a significant challenge to the industrialization of batteries incorporating these materials. This limitation can be attributed to various factors, with the intrinsic behavior of the crystal structure during the cycle process being a key contributor. These factors include phase transition induced cracks, reduced Li active sites due to Li/Ni mixing, and slower Li+ migration. In addition, the presence of synthesis-induced heterogeneous phases and lattice defects cannot be disregarded as they also contribute to the degradation in performance. Therefore, gaining a profound understanding of the intricate relationship among material synthesis, structure, and performance is imperative for the development of LiTMO2. This paper highlights the pivotal role of structural play in LiTMO2 materials and provides a comprehensive overview of how various control factors influence the specific pathways of structural evolution during the synthesis process. In addition, it summarizes the scientific challenges associated with diverse modification approaches currently employed to address the cyclic failure of materials. The overarching goal is to provide readers with profound insights into the study of LiTMO2.

Re-evaluation of battery-grade lithium purity toward sustainable batteries

Recently, the cost of lithium-ion batteries has risen as the price of lithium raw materials has soared and fluctuated. Notably, the highest cost of lithium production comes from the impurity elimination process to satisfy the battery-grade purity of over 99.5%. Consequently, re-evaluating the impact of purity becomes imperative for affordable lithium-ion batteries. In this study, we unveil that a 1% Mg impurity in the lithium precursor proves beneficial for both the lithium production process and the electrochemical performance of resulting cathodes. This is attributed to the increased nucleation seeds and unexpected site-selective doping effects. Moreover, when extended to an industrial scale, low-grade lithium is found to reduce production costs and CO2 emissions by up to 19.4% and 9.0%, respectively. This work offers valuable insights into the genuine sustainability of lithium-ion batteries.

Elucidating Phase Transformation and Surface Amorphization of Li7 La3 Zr2 O12 by In Situ Heating TEM

Garnet-type Li7 La3 Zr2 O12 (LLZO) solid-state electrolytes hold great promise for the next-generation all-solid-state batteries. An in-depth understanding of the phase transformation during synthetic processes is required for better control of the crystallinity and improvement of the ionic conductivity of LLZO. Herein, the phase transformation pathways and the associated surface amorphization are comparatively investigated during the sol-gel and solid-state syntheses of LLZO using in situ heating transmission electron microscopy (TEM). The combined ex situ X-ray diffraction and in situ TEM techniques are used to reveal two distinct phase transformation pathways (precursors → La2 Zr2 O7  → LLZO and precursors → LLZO) and the subsequent layer-by-layer crystal growth of LLZO on the atomic scale. It is also demonstrated that the surface amorphization surrounding the LLZO crystals is sensitive to the postsynthesis cooling rate and significantly affects the ionic conductivity of pelletized LLZO. This work brings up a critical but often overlooked issue that may greatly exacerbate the Li-ion conductivity by undesired synthetic conditions, which can be leveraged to ameliorate the overall crystallinity to improve the electrochemical performance of LLZO. These findings also shed light on the significance of optimizing surface structure to ensure superior performance of Li-ion conductors.

In Situ Constructing Ultrastable Mechanical Integrity of Single-Crystalline LiNi0.9 Co0.05 Mn0.05 O2 Cathode by Interior and Exterior Decoration Strategy

Planar gliding along with anisotropic lattice strain of single-crystalline nickel-rich cathodes (SCNRC) at highly delithiated states will induce severe delamination cracking that seriously deteriorates LIBs' cyclability. To address these issues, a novel lattice-matched MgTiO3 (MTO) layer, which exhibits same lattice structure as Ni-rich cathodes, is rationally constructed on single-crystalline LiNi0.9 Co0.05 Mn0.05 O2 (SC90) for ultrastable mechanical integrity. Intensive in/ex situ characterizations combined with theoretical calculations and finite element analysis suggest that the uniform MTO coating layer prevents direct contact between SC90 and organic electrolytes and enables rapid Li-ion diffusion with depressed Li-deficiency, thereby stabilizing the interfacial structure and accommodating the mechanical stress of SC90. More importantly, a superstructure is simultaneously formed in SC90, which can effectively alleviate the anisotropic lattice changes and decrease cation mobility during successive high-voltage de/intercalation processes. Therefore, the as-acquired MTO-modified SC90 cathode displays desirable capacity retention and high-voltage stability. When paired with commercial graphite anodes, the pouch-type cells with the MTO-modified SC90 can deliver a high capacity of 175.2 mAh g-1 with 89.8% capacity retention after 500 cycles. This lattice-matching coating strategy demonstrate a highly effective pathway to maintain the structural and interfacial stability in electrode materials, which can be a pioneering breakthrough in commercialization of Ni-rich cathodes.

Asynchronous domain dynamics and equilibration in layered oxide battery cathode

To improve lithium-ion battery technology, it is essential to probe and comprehend the microscopic dynamic processes that occur in a real-world composite electrode under operating conditions. The primary and secondary particles are the structural building blocks of battery cathode electrodes. Their dynamic inconsistency has profound but not well-understood impacts. In this research, we combine operando coherent multi-crystal diffraction and optical microscopy to examine the chemical dynamics in local domains of layered oxide cathode. Our results not only pinpoint the asynchronicity of the lithium (de)intercalation at the sub-particle level, but also reveal sophisticated diffusion kinetics and reaction patterns, involving various localized processes, e.g., chemical onset, reaction front propagation, domains equilibration, particle deformation and motion. These observations shed new lights onto the activation and degradation mechanisms of state-of-the-art battery cathode materials.

Fundamentals, status and challenges of direct recycling technologies for lithium ion batteries

Advancement in energy storage technologies is closely related to social development. However, a significant conflict has arisen between the explosive growth in battery demand and resource availability. Facing the upcoming large-scale disposal problem of spent lithium-ion batteries (LIBs), their recycling technology development has become key. Emerging direct recycling has attracted widespread attention in recent years because it aims to 'repair' the battery materials, rather than break them down and extract valuable products from their components. To achieve this goal, a profound understanding of the failure mechanisms of spent LIB electrode materials is essential. This review summarizes the failure mechanisms of LIB cathode and anode materials and the direct recycling strategies developed. We systematically explore the correlation between the failure mechanism and the required repair process to achieve efficient and even upcycling of spent LIB electrode materials. Furthermore, we systematically introduce advanced in situ characterization techniques that can be utilized for investigating direct recycling processes. We then compare different direct recycling strategies, focussing on their respective advantages and disadvantages and their applicability to different materials. It is our belief that this review will offer valuable guidelines for the design and selection of LIB direct recycling methods in future endeavors. Finally, the opportunities and challenges for the future of battery direct recycling technology are discussed, paving the way for its further development.

Isotropic Microstrain Relaxation in Ni-Rich Cathodes for Long Cycling Lithium Ion Batteries

Developing isotropic-dominated microstrain relaxation is a vital step toward the enhancement of cyclic performance and thermal stability for high-energy-density Ni-rich cathodes. Here, a microstructure engineering strategy is employed for synthesizing the elongated primary particles radially aligned Ni-rich cathodes only by regulating the precipitation rates of cations and the distributions of flow field. The as-obtained cathode also exhibits an enlarged lattice distance and highly exposed (003) plane. The high aspect ratio and favorable atomic arrangement of primary particles not only enable isotropic strain relaxation for effectively suppressing microcrack formation and propagation, but also facilitate Li-ion diffusion with greatly reduced Li/Ni mixing. Consequently, it shows obvious superiority in the high-rate, long-cycle life, and thermal stability compared with the conventional counterparts. After modification, an exceptionally long life is achieved with a capacity retention of 90.1% at 1C and 84.3% at 5C after 1500 cycles within 3.0-4.3 V in a 1.5-Ah pouch cell. This work offers a universal strategy to achieve isotropic strain distribution for conveniently enhancing the durability of Ni-rich cathodes.

Osmotically Delaminated Silicate Nanosheet-Coated NCM for Ultra-Stable Li+ Storage and Chemical Stability Toward Long-Term Air Exposure

To ensure the safety and performance of lithium-ion batteries (LIBs), a rational design and optimization of suitable cathode materials are crucial. Lithium nickel cobalt manganese oxides (NCM) represent one of the most popular cathode materials for commercial LIBs. However, they are limited by several critical issues, such as transition metal dissolution, formation of an unstable cathode-electrolyte interphase (CEI) layer, chemical instability upon air exposure, and mechanical instability. In this work, coating fabricated by self-assembly of osmotically delaminated sodium fluorohectorite (Hec) nanosheets onto NCM (Hec-NCM) in a simple and technically benign aqueous wet-coating process is reported first. Complete wrapping of NCM by high aspect ratio (>10 000) nanosheets is enabled through an electrostatic attraction between Hec nanosheets and NCM as well as by the superior mechanical flexibility of Hec nanosheets. The coating significantly suppresses mechanical degradation while forming a multi-functional CEI layer. Consequently, Hec-NCM delivers outstanding capacity retention for 300 cycles. Furthermore, due to the exceptional gas barrier properties of the few-layer Hec-coating, the electrochemical performance of Hec-NCM is maintained even after 6 months of exposure to the ambient atmosphere. These findings suggest a new direction of significantly improving the long-term stability and activity of cathode materials by creating an artificial CEI layer.

Origin and Regulation of Interface Fusion during Synthesis of Single-Crystal Ni-Rich Cathodes

Interface fusion plays a key role in constructing Ni-based single-crystal cathodes, and is governed by the atomic migration related to kinetics. However, the interfacial atom migration path and its control factors are lack of clearly understanding. Herein, we systematically probe the solid-state synthesis mechanism of single-crystal LiNi_0.92 Co_0.04 Mn_0.04 O₂ , including the effects of precursor size, Li/transition metal (TM) ratio and sintering temperature on the structure. Multi-dimensional analysis unravels that thermodynamics drives interface atoms migration through intermediate state (i.e., cation mixing phase) to induce grain boundary fusion. Moreover, we demonstrate that smaller precursor size (<6 μm), lager Li/TM ratio (>1.0) and higher temperature (≥810 °C) are conducive to promote the growth of the intermediate state due to reaction kinetics enhancement, and ultimately strengthen the atomic migration-induced interface fusion.

Topotactic Transformation of Surface Structure Enabling Direct Regeneration of Spent Lithium-Ion Battery Cathodes

Recycling spent lithium-ion batteries (LIBs) has become an urgent task to address the issues of resource shortage and potential environmental pollution. However, direct recycling of the spent LiNi_0.5Co_0.2Mn_0.3O₂ (NCM523) cathode is challenging because the strong electrostatic repulsion from a transition metal octahedron in the lithium layer provided by the rock salt/spinel phase that is formed on the surface of the cycled cathode severely disrupts Li⁺ transport, which restrains lithium replenishment during regeneration, resulting in the regenerated cathode with inferior capacity and cycling performance. Here, we propose the topotactic transformation of the stable rock salt/spinel phase into Ni_0.5Co_0.2Mn_0.3(OH)₂ and then back to the NCM523 cathode. As a result, a topotactic relithiation reaction with low migration barriers occurs with facile Li⁺ transport in a channel (from one octahedral site to another, passing through a tetrahedral intermediate) with weakened electrostatic repulsion, which greatly improves lithium replenishment during regeneration. In addition, the proposed method can be extended to repair spent NCM523 black mass, spent LiNi_0.6Co_0.2Mn_0.2O₂, and spent LiCoO₂ cathodes, whose electrochemical performance after regeneration is comparable to that of the commercial pristine cathodes. This work demonstrates a fast topotactic relithiation process during regeneration by modifying Li⁺ transport channels, providing a unique perspective on the regeneration of spent LIB cathodes.

Cooperative Electronic Structure Modulator of Fe Single-Atom Electrocatalyst for High Energy and Long Cycle Li-S Pouch Cell

High-energy and long cycle lithium-sulfur (Li-S) pouch cells are limited by the insufficient capacities and stabilities of their cathodes under practical electrolyte/sulfur (E/S), electrolyte/capacity (E/C), and negative/positive (N/P) ratios. Herein, an advanced cathode comprising highly active Fe single-atom catalysts (SACs) is reported to form 320.2 W h kg^-1 multistacked Li-S pouch cells with total capacity of ≈1 A h level, satisfying low E/S (3.0), E/C (2.8), and N/P (2.3) ratios and high sulfur loadings (8.4 mg cm^-2 ). The high-activity Fe SAC is designed by manipulating its local environments using electron-exchangeable binding (EEB) sites. Introducing EEB sites comprising two different types of S species, namely, thiophene-like-S (-S) and oxidized-S (-SO₂ ), adjacent to Fe SACs promotes the kinetics of the Li₂ S redox reaction by providing additional binding sites and modulating the Fe d-orbital levels via electron exchange with Fe. The -S donates the electrons to the Fe SACs, whereas -SO₂ withdraws electrons from the Fe SACs. Thus, the Fe d-orbital energy level can be modulated by the different -SO₂ /-S ratios of the EEB site, controlling the electron donating/withdrawing characteristics. This desirable electrocatalysis is maximized by the intimate contact of the Fe SACs with the S species, which are confined together in porous carbon.

Solid-State Reaction Heterogeneity During Calcination of Lithium-Ion Battery Cathode

During solid-state calcination, with increasing temperature, materials undergo complex phase transitions with heterogeneous solid-state reactions and mass transport. Precise control of the calcination chemistry is therefore crucial for synthesizing state-of-the-art Ni-rich layered oxides (LiNi_1-x-y Co_x Mn_y O₂ , NRNCM) as cathode materials for lithium-ion batteries. Although the battery performance depends on the chemical heterogeneity during NRNCM calcination, it has not yet been elucidated. Herein, through synchrotron-based X-ray, mass spectrometry microscopy, and structural analyses, it is revealed that the temperature-dependent reaction kinetics, the diffusivity of solid-state lithium sources, and the ambient oxygen control the local chemical compositions of the reaction intermediates within a calcined particle. Additionally, it is found that the variations in the reducing power of the transition metals (i.e., Ni, Co, and Mn) determine the local structures at the nanoscale. The investigation of the reaction mechanism via imaging analysis provides valuable information for tuning the calcination chemistry and developing high-energy/power density lithium-ion batteries.

Monitoring the Formation of Nickel-Poor and Nickel-Rich Oxide Cathode Materials for Lithium-Ion Batteries with Synchrotron Radiation

The syntheses of Ni-poor (NCM111, LiNi_1/3Co_1/3Mn_1/3O₂) and Ni-rich (NCM811 LiNi_0.8Co_0.1Mn_0.1O₂) lithium transition-metal oxides (space group R3̅m) from hydroxide precursors (Ni_1/3Co_1/3Mn_1/3(OH)₂, Ni_0.8Co_0.1Mn_0.1(OH)₂) are investigated using in situ synchrotron powder diffraction and near-edge X-ray absorption fine structure spectroscopy. The development of the layered structure of these two cathode materials proceeds via two utterly different reaction mechanisms. While the synthesis of NCM811 involves a rock salt-type intermediate phase, NCM111 reveals a layered structure throughout the entire synthesis. Moreover, the necessity and the impact of a preannealing step and a high-temperature holding step are discussed.

Surface Stabilization of Cobalt-Free LiNiO2 with Niobium for Lithium-Ion Batteries

Lithium nickel oxide (LiNiO₂) is a promising next-generation cathode material for lithium-ion batteries (LIBs), offering exceptionally high specific capacity and reduced material cost. However, the poor structural, surface, and electrochemical stabilities of LiNiO₂ result in rapid loss of capacity during prolonged cycling, making it unsuitable for application in commercial LIBs. Herein, we demonstrate that incorporation of a small amount of niobium effectively suppresses the structural and surface degradation of LiNiO₂. The niobium-treated LiNiO₂ retains 82% of its initial capacity after 500 cycles in full cells with a graphite anode compared to 73% for untreated LiNiO₂. We utilize a facile method for incorporating niobium, which yields Li_xNbO_y phase formation as a surface coating on the primary particles. Through a combination of X-ray diffraction, electron microscopy, and electrochemical analyses, we show that the resulting niobium coating reduces active material loss over long-term cycling and enhances lithium-ion diffusion kinetics. The enhanced structural integrity and electrochemical performance of the niobium-treated LiNiO₂ are correlated to a reduction in the formation of nanopore defects during cycling compared to the untreated LiNiO₂.

Scalable Advanced Li(Ni0.8Co0.1Mn0.1)O2 Cathode Materials from a Slug Flow Continuous Process

Li[Ni_0.8Co_0.1Mn_0.1]O₂ (LNCMO811) is the most studied cathode material for next-generation lithium-ion batteries with high energy density. However, available synthesis methods are time-consuming and complex, restricting their mass production. A scalable manufacturing process for producing NCM811 hydroxide precursors is vital for commercialization of the material. In this work, a three-phase slug flow reactor, which has been demonstrated for its ease of scale-up, better synthetic control, and excellent uniform mixing, was developed to control the initial stage of the coprecipitation of NCM811 hydroxide. Furthermore, an equilibrium model was established to predict the yield and composition of the final product. The homogeneous slurry from the slug flow system was obtained and then transferred into a ripening vessel for the necessary ripening process. Finally, the lithium-nickel-cobalt-manganese oxide was obtained through the calcination of the slug flow-derived precursor with lithium hydroxide, having a tap density of 1.3 g cm^-3 with a well-layered structure. As-synthesized LNCMO811 shows a high specific capacity of 169.5 mAh g^-1 at a current rate of 0.1C and a long cycling stability of 1000 cycling with good capacity retention. This demonstration provides a pathway toward scaling up the cathode synthesis process for large-scale battery applications.