Search Results (26)

The growing demand for high-energy, safe, and sustainable lithium-ion batteries has increased interest in nickel-rich cathode materials and solid-state electrolytes. This study presents a scalable wet-processing method for fabricating composite cathodes for all-solid-state batteries. The cathodes studied herein are high-nickel LiNi_0.90Mn_0.05Co_0.05O₂, NMC955, the sulfide-based electrolyte Li₆PS₅Cl, and alternative binders—polyvinyl alcohol (PVA) and polyisobutylene (PIB)—dispersed in toluene, a non-polar solvent compatible with the electrolyte. After fabrication, the cathodes were characterized using SEM/EDX, sheet resistance, and Hall effect measurements. Electrochemical tests were additionally performed in all-solid-state battery half-cells comprising the synthesized cathodes, lithium metal anodes, and Li₆PS₅Cl as the separator and electrolyte. The results show that both PIB and PVA formulations yielded conductive cathodes with stable microstructures and uniform particle distribution. Electrochemical characterization exposed that the PVA-based cathode outperformed the PIB-based counterpart, achieving the theoretical capacity of 192 mAh·g⁻¹ even at 1C, whereas the PIB cathode reached a maximum capacity of 145 mAh.g⁻¹ at C/40. Post-mortem analysis confirmed the structural integrity of the cathodes. These findings demonstrate the viability of NMC955 as a high-capacity cathode material compatible with solid-state systems. Full article

Nickel-rich layered oxides such as LiNi_xMn_yCo_zO₂ (NMC), LiNi_xCo_yAl_zO₂ (NCA), and LiNi_xMn_yCo_zAl_{(1–x–y–z)}O₂ (NMCA), where x ≥ 0.6, have emerged as key cathode materials in lithium-ion batteries due to their high operating voltage and superior energy density. These materials, characterized by low cobalt content, offer a promising path toward sustainable and cost-effective energy storage solutions. However, their electrochemical performance remains below theoretical expectations, primarily due to challenges related to structural instability, limited thermal safety, and suboptimal cycle life. Intensive research efforts have been devoted to addressing these issues, resulting in substantial performance improvements and enabling the development of next-generation lithium-ion batteries with higher nickel content and reduced cobalt dependency. In this review, we present recent advances in material design and engineering strategies to overcome the problems limiting their electrochemical performance (cation mixing, phase stability, oxygen release, microcracks during cycling). These strategies include synthesis methods to optimize the morphology (size of the particles, core–shell and gradient structures), surface modifications of the Ni-rich particles, and doping. A detailed comparison between these strategies and the synergetic effects of their combination is presented. We also highlight the synergistic role of compatible lithium salts and electrolytes in achieving state-of-the-art nickel-rich lithium-ion batteries. Full article

The increasing demand for lithium-ion batteries (LIBs) and their limited lifespan emphasize the urgent need for sustainable recycling strategies. This study investigates the application of tetrabutylphosphonium-based ionic liquids (ILs) as alternative leaching agents for recovering critical metals, Li(I), Co(II), Ni(II), and Mn(II), from spent NMC cathode materials. Initial screening experiments evaluated the leaching efficiencies of nine tetrabutylphosphonium-based ILs for Co(II), Ni(II), Mn(II), and Li(I), revealing distinct metal dissolution behaviors. Three ILs containing HSO₄⁻, EDTA²⁻, and DTPA³⁻ anions exhibited the highest leaching performance and were selected for further optimization. Key leaching parameters, including IL and acid concentrations, temperature, time, and solid-to-liquid ratio, were systematically adjusted, achieving leaching efficiencies exceeding 90%. Among the tested systems, [TBP][HSO₄] enabled near-complete metal dissolution (~100%) even at room temperature. Furthermore, an aqueous biphasic system (ABS) was investigated utilizing [TBP][HSO₄] in combination with ammonium sulfate, enabling the complete extraction of all metals into the salt-rich phase while leaving the IL phase metal-free and potentially suitable for reuse, indicating the feasibility of integrating leaching and extraction into a continuous, interconnected process. This approach represents a promising step forward in LIB recycling, highlighting the potential for sustainable and efficient integration of leaching and extraction within established hydrometallurgical frameworks. Full article

With the growing demand for metals driven by technological advancements and population growth, recycling lithium-ion batteries has become vital for protecting the environment and recovering valuable materials. Developing sustainable recycling technologies is now more essential than ever. This paper focuses on using electrodialysis to process a leach solution of LiNi_0.33Mn_0.33Co_0.33O₂ (NMC 111) cathode materials leached with citric acid. This study demonstrates that the complexing properties of citrate anions contribute to the efficient separation of Li from Ni, Co, and Mn by electrodialysis. This is achieved by promoting the formation of anionic species for Ni, Co, and Mn while maintaining Li in its cationic form. The leach solution was produced under the following optimal experimental conditions to reach a final pH of 5 and high leaching efficiency: a citric acid concentration of 1 mol L⁻¹, a leaching temperature of 45 °C, a leaching time of 5 h, a liquid/solid ratio of 100 g/L, and 8 vol.% H₂O₂. These conditions resulted in leaching efficiencies of 89.3% for Ni, 95.1% for Co, 77.1% for Mn, and 92.9% for Li. This solution led to the formation of a lithium-rich supernatant and a precipitate. The supernatant was then used as the feed solution for electrodialysis. Pure lithium was successfully separated with a faradic efficiency of 71.4% with a commercial cation-exchange membrane. This strategy enables selective lithium recovery while minimizing membrane fouling during the process. Full article

Lithium nickel manganese cobalt oxides (NMCs) are widely used as cathode materials in commercial batteries. Efforts have been made to enhance battery energy density and stability by adjusting the element ratio. Nickel-rich NMC shows promise due to its high capacity; however, its commercial viability is hindered by severe capacity fade, primarily caused by poor mechanical stability. To address this, understanding the chemo-mechanical behavior of Ni-rich NMC is crucial. The mechanical failure of Ni-rich NMC materials during battery operation has been widely studied through theoretical approaches to identify possible solutions. The elastic properties are key parameters for structural analysis. However, experimental data on NMC materials are scarce due to the inherent difficulty of measuring the properties of electrode active particles at such a small scale. In this study, we employ molecular dynamics (MDs) simulations to investigate the elastic properties of NMC materials with varying compositions (NMC111, NMC532, NMC622, NMC721, and NMC811). Our results reveal that elasticity increases with nickel content, ranging from 200 GPa for NMC111 to 290 GPa for NMC811. We further analyze the contributing factors to this trend by examining the individual components of the elastic properties. The simulation results provide valuable input parameters for theoretical models and continuum simulations, offering insights into strategies for reducing the mechanical instability of Ni-rich NMC materials. Full article

Composite solid electrolytes are gaining interest regarding their use in Li-metal solid-state batteries. Although high ceramic content improves the electrochemical stability of ceramic-rich composite separators (C-SCE), the polymeric matrix also plays a vital role. In the first generation of C-SCE separators with a PEO-based matrix, the addition of 90–95 wt% of Li_6.45Al_0.05La₃Zr_1.6Ta_0.4O₁₂ (LLZO) does not make C-SCE stable for cell cycling with high-voltage (HV) cathodes. For the next iteration, the objective was to find an HV-stable polymeric matrix for C-SCEs. Herein, we report results on optimizing C-SCE separators with different ceramics and polymers which can craft the system towards better stability with NMC622-based composite cathodes. Both LLZO and Li_1.3Al_0.3Ti_1.7(PO₄)₃ (LATP) were utilized as ceramic components in C-SCE separators. Poly(diallyldimethylammonium) bis(trifluoromethanesulfonyl)imide (PDDA-TFSI) and poly (vinylidene fluoride-co-hexafluoropropylene) (PVDF-HFP) were used as polymers in the “polymer/LiTFSI/plasticizer”-based matrix. The initial phase of the selection criteria for the separator matrix involved assessing mechanical stability and ionic conductivity. Two optimized separator formulations were then tested for their electrochemical stability with both Li metal and HV composite cathodes. The results showed that Li/NMC622 cells with LP70_PVDF_HFP and LZ70_PDDA-TFSI separators exhibited more stable cycling performance compared to those with LZ90_PEO300k-based separators. Full article

High Ni-content LiNi_xMn_yCo_zO₂ (NMC) cathodes (with x ≥ 0.8, x + y + z = 1) have gained attention recently for their high energy density in electric vehicle (EV) Li-ion batteries. However, Ni-rich cathodes pose challenges in capacity retention due to inherent structural and surface redox instabilities. One promising strategy is to make the Ni-rich NMC material in the form of single-crystal micron-sized particles, as they resist intergranular and surface degradation during cycling. Among various methods to synthesize single-crystal NMC (SC-NMC) particles, molten-salt-assisted calcination offers distinct processing advantages but at present, is not yet optimized or mechanistically clarified to yield the desired control over crystal growth and morphology. In this project, molten-salt-mediated transformation of Ni_0.85Mn_0.05Co_0.15(OH)₂ precursor (P-NMC) particles to LiNi_0.85Mn_0.05Co_0.15O₂ particles is investigated in terms of the crystal growth mechanism and its electrochemical response. Unlike previous studies that involved large volumes of molten salt, using a smaller volume of molten KCl is found to result in larger primary particles with improved cycling performance achieved via partial reactive dissolution and heterogeneous nucleation growth, suggesting that the ratio of molten salt volume to NMC mass is an important parameter in the synthesis of single-crystal Ni-rich NMC materials. Full article

All-solid-state batteries with a lithium negative electrode and a ceramic electrolyte are key toward high energy density. To ensure a safe, fast, accurate, and cost-effective development of this technology, the experimental methodology must be supported by the numerical modeling approach. This work proposes and describes an electrochemical model of a Li₇La₃Zr₂O₁₂ (LLZO) and Ni-rich NMC-based lithium cell with a deformable lithium negative electrode. Simulations were computed using the finite element method at different operating conditions to demonstrate the scope of the modeling work. Discharge rate tests, deformation tracking, geometric defect investigation, and polarization decomposition are described. Theoretical validation of the mass balance, the stripping rate, the ohmic polarization, and the mesh deformation demonstrated the consistency of the volumetric deformation strategy. We demonstrated in this study a deformable modeling strategy, which was found to be useful for the electrostripping analysis of anodic geometry defects during discharge. Non-uniformity in the lithium stripping rate was found along the anodic interface with defects, and this non-uniformity was accentuated with a higher discharge rate. The cell’s discharge potential was decomposed by considering the equilibrium potential and the polarizations of the main components of the cell. This post-processing was found to be useful for the understanding of the cell’s behavior. Full article

This study focuses on NMC 811 (LiNi_0.8Mn_0.1Co_0.1O₂), a promising material for high-capacity batteries, and investigates the challenges associated with its use, specifically the formation of the cathode electrolyte interphase (CEI) layer due to chemical reactions. This layer is a consequence of the position of the Lowest Unoccupied Molecular Orbital (LUMO) energy level of NMC 811 that is close to the Highest Occupied Molecular Orbital (HOMO) level of liquid electrolytes, resulting in electrolyte oxidation and cathode surface alterations during charging. A stable CEI layer can mitigate further degradation by reducing the interaction between the reactive cathode material and the electrolyte. Our research analyzed the CEI layer on NMC 811 using advanced techniques, such as 4D-STEM ACOM (automated crystal orientation mapping) and STEM-EDX, focusing on the effects of different charging voltages (4.3 V and 4.5 V). The findings revealed varying degrees of degradation and the formation of a fluorine-rich layer on the secondary particles. Detailed analysis showed that the composition of this layer differed based on the voltage: only LiF at 4.5 V and a combination of lithium fluoride (LiF) and lithium hydroxide (LiOH) at 4.3 V. Despite LiF’s known stability as a CEI protective layer, our observations indicate that it does not effectively prevent degradation in NMC 811. The study concluded that impurities and unwanted chemical reactions leading to suboptimal CEI formation are inevitable. Therefore, future efforts should focus on developing protective strategies for NMC 811, such as the use of specific additives or coatings. Full article

Ni-rich LiNi_xMn_yCo_1−x−yO₂ (NMC) materials have been adopted in a range of applications, including electric vehicles. The recycled NMC material from a spent cell would be much more valuable if it could be upgraded to a Ni-rich, more energy-dense version of the material. This work demonstrates a simple, inexpensive, and facile method to upcycle LiNi_1/3Mn_1/3Co_1/3O₂ (NMC111, 160 mAh∙g⁻¹), a cathode used in early generations of electric vehicle batteries, to LiNi_0.8Mn_0.1Co_0.1O₂ (NMC811, 190 mAh∙g⁻¹), a more energy-dense cathode material. In this study, a preliminary investigation into a room-temperature eutectic synthesis of NMC811 is performed using NMC111, LiOH, and nickel nitrate as precursors. The synthesized material showed the desired crystal structure and stoichiometry, though the cycle life and Li diffusion coefficient need improvement when compared to commercially available NMC811. This study demonstrates an interesting proof of concept of the room-temperature eutectic synthesis process for LIB cathodes and could be improved by tuning the synthesis conditions. Full article

Surface coating has become an effective approach to improve the electrochemical performance of Ni-rich cathode materials. In this study, we investigated the nature of an Ag coating layer and its effect on electrochemical properties of the LiNi_0.8Co_0.1Mn_0.1O₂ (NCM811) cathode material, which was synthesized using 3 mol.% of silver nanoparticles by a facile, cost-effective, scalable and convenient method. We conducted structural analyses using X-ray diffraction, Raman spectroscopy, and X-ray photoelectron spectroscopy, which revealed that the Ag nanoparticle coating did not affect the layered structure of NCM811. The Ag-coated sample had less cation mixing compared to the pristine NMC811, which could be attributed to the surface protection of Ag coating from air contamination. The Ag-coated NCM811 exhibited better kinetics than the pristine one, which is attributed to the higher electronic conductivity and better layered structure provided by the Ag nanoparticle coating. The Ag-coated NCM811 delivered a discharge capacity of 185 mAh·g⁻¹ at the first cycle and 120 mAh·g⁻¹ at the 100th cycle, respectively, which is better than the pristine NMC811. Full article

Electrochemical stress induced by the charging/discharging of electrode materials strongly affects the lifetime of lithium-ion batteries (LIBs) by regulating mechanical failures. Electrochemical stress is caused by a change in the local volume of the active materials associated with the lithium-ion concentration. The local volume change of certain active materials, such as nickel-rich LiNi_xMn_yCo_zO₂ (NMC), varies nonlinearly with the lithium content, which has not been considered in the stress calculations in previous studies. In this paper, the influence of nonlinear local volume change on the mechanical response of NMC-active materials is investigated numerically. The goal is achieved by using a concentration-dependent partial molar volume calculated from the previously obtained local volume change experimental results. A two-dimensional axisymmetric model was developed to perform finite element simulations by fully coupling lithium diffusion and stress generation at a single particle level. The numerical results demonstrate that (1) the global volume change of the particle evolves nonlinearly, (2) the stress response correlates with the rate of change of the active particle’s volume, and (3) stress–concentration coupling strongly affects the concentration levels inside the particle. We believe this is the first simulation study that highlights the effect of a concentration-dependent partial molar volume on diffusion-induced stresses in NMC materials. The proposed model provides insight into the design of next-generation NMC electrode materials to achieve better structural stability by reducing mechanical cracking issues. Full article

Development in high-rate electrode materials capable of storing vast amounts of charge in a short duration to decrease charging time and increase power in lithium-ion batteries is an important challenge to address. Here, we introduce a synthesis strategy with a series of composition-controlled NMC cathodes, including LiNi_0.2Mn_0.6Co_0.2O₂(NMC262), LiNi_0.3Mn_0.5Co_0.2O₂(NMC352), and LiNi_0.4Mn_0.4Co_0.2O₂(NMC442). A very high-rate performance was achieved for Mn-rich LiNi_0.2Mn_0.6Co_0.2O₂ (NMC262). It has a very high initial discharge capacity of 285 mAh g⁻¹ when charged to 4.7 V at a current of 20 mA g⁻¹ and retains the capacity of 201 mAh g⁻¹ after 100 cycles. It also exhibits an excellent rate capability of 138, and 114 mAh g⁻¹ even at rates of 10 and 15 C (1 C = 240 mA g⁻¹). The high discharge capacities and excellent rate capabilities of Mn-rich LiNi_0.2Mn_0.6Co_0.2O₂ cathodes could be ascribed to their structural stability, controlled particle size, high surface area, and suppressed phase transformation from layered to spinel phases, due to low cation mixing and the higher oxidation state of manganese. The cathodic and anodic diffusion coefficient of the NMC262 electrode was determined to be around 4.76 × 10⁻¹⁰ cm² s⁻¹ and 2.1 × 10⁻¹⁰ cm² s⁻¹, respectively. Full article

Femtosecond ultrafast-laser micro-patterning was employed to prepare a three-dimensional (3D) structure for the tape-casting Ni-rich LiNi_0.8Mn_0.1Co_0.1O₂ (NMC811) cathode. The influences of laser structuring on the electrochemical performance of NMC811 were investigated. The 3D-NMC811 cathode retained capacities of 77.8% at 2 C of initial capacity at 0.1 C, which was thrice that of 2D-NMC811 with an initial capacity of 27.8%. Cyclic voltammetry (CV) and impedance spectroscopy demonstrated that the 3D electrode improved the Li⁺ ion transportation at the electrode–electrolyte interface, resulting in a higher rate capability. The diffusivity coefficient D_Li+, calculated by both CV and electrochemical impedance spectroscopy, revealed that 3D-NMC811 delivered faster Li⁺ ion transportation with higher D_Li+ than that of 2D-NMC811. The laser ablation of the active material also led to a lower charge–transfer resistance, which represented lower polarization and improved Li⁺ ion diffusivity. Full article

Nickel-rich LiNi_0.8Mn_0.1Co_0.1O₂ (NMC811) is one of the most promising Li-ion battery cathode materials and has attracted the interest of the automotive industry. Nevertheless, storage conditions can affect its properties and performance. In this work, both NMC811 powder and electrodes were storage-aged for one year under room conditions. The aged powder was used to prepare electrodes, and the performance of these two aged samples was compared with reference fresh NMC811 electrodes in full Li-ion coin cells using graphite as a negative electrode. The cells were subjected to electrochemical as well as ante- and postmortem characterization. The performance of the electrodes from aged NM811 was beyond expectations: the cycling performance was high, and the power capability was the highest among the samples analyzed. Materials characterization revealed modifications in the crystal structure and the surface layer of the NMC811 during the storage and electrode processing steps. Differences between aged and fresh electrodes were explained by the formation of a resistive layer at the surface of the former. However, the ageing of NMC811 powder was significantly mitigated during the electrode processing step. These novel results are of interest to cell manufacturers for the widespread implementation of NMC811 as a state-of-the-art cathode material in Li-ion batteries. Full article