Alumina - Stabilized SEI and CEI in Potassium Metal Batteries.

Aluminum oxide (Al2O3) nanopowder is spin-coated onto both sides of commercial polypropene separator to create artificial solid-electrolyte interphase (SEI) and artificial cathode electrolyte interface (CEI) in potassium metal batteries (KMBs). This significantly enhances the stability, including of KMBs with Prussian Blue (PB) cathodes. For example, symmetric cells are stable after 1,000 cycles at 0.5 mA/cm2-0.5 mAh/cm2 and 3.0 mA/cm2-0.5 mAh/cm2. Alumina modified separators promote electrolyte wetting and increase ionic conductivity (0.59 vs. 0.2 mS/cm) and transference number (0.81 vs. 0.23). Cryo-stage focused ion beam (cryo-FIB) analysis of cycled modified anode demonstrates dense and planar electrodeposits, versus unmodified baseline consisting of metal filaments (dendrites) interspersed with pores and SEI. Alumina-modified CEI also suppresses elemental Fe crossover and reduces cathode cracking. Mesoscale modeling of metal - SEI interactions captures crucial role of intrinsic heterogeneities, illustrating how artificial SEI affects reaction current distribution, conductivity and morphological stability.

Interdependence of Support Wettability -Electrodeposition Rate - Sodium Metal Anode and SEI Microstructure.

This study examines how current collector support chemistry (sodiophilic intermetallic Na2Te vs. sodiophobic baseline Cu) and electrodeposition rate affect microstructure of sodium metal and its solid electrolyte interphase (SEI). Capacity and current (6 mAh cm-2, 0.5-3 mA cm-2) representative of commercially relevant mass loading in anode-free sodium metal battery (AF-SMBs) are analyzed. Synchrotron X-ray nanotomography and grazing-incidence wide-angle X-ray scattering (GIWAXS) are combined with cryogenic focused ion beam (cryo-FIB) microscopy. Highlighted are major differences in film morphology, internal porosity, and crystallographic preferred orientation e.g. (110) vs. (100) and (211) with support and deposition rate. Within the SEI, sodium fluoride (NaF) is more prevalent with Te-Cu versus sodium hydride (NaH) and sodium hydroxide (NaOH) with baseline Cu. Due to competitive grain growth the preferred orientation of sodium crystallites depends on film thickness. Mesoscale modelling delineates the role of SEI (ionic conductivity, morphology) on electrodeposit growth and onset of electrochemical instability.

Polymorphism of garnet solid electrolytes and its implications for grain-level chemo-mechanics.

Understanding and mitigating filament formation, short-circuit and solid electrolyte fracture is necessary for advanced all-solid-state batteries. Here, we employ a coupled far-field high-energy diffraction microscopy and tomography approach for assessing the chemo-mechanical behaviour for dense, polycrystalline garnet (Li7La3Zr2O12) solid electrolytes with grain-level resolution. In situ monitoring of grain-level stress responses reveals that the failure mechanism is stochastic and affected by local microstructural heterogeneity. Coupling high-energy X-ray diffraction and far-field high-energy diffraction microscopy measurements reveals the presence of phase heterogeneity that can alter local chemo-mechanics within the bulk solid electrolyte. These local regions are proposed to be regions with the presence of a cubic polymorph of LLZO, potentially arising from local dopant concentration variation. The coupled tomography and FF-HEDM experiments are combined with transport and mechanics modelling to illustrate the degradation of polycrystalline garnet solid electrolytes. The results showcase the pathways for processing high-performing solid-state batteries.

Effect of crystallite geometries on electrochemical performance of porous intercalation electrodes by multiscale operando investigation.

Lithium-ion batteries are yet to realize their full promise because of challenges in the design and construction of electrode architectures that allow for their entire interior volumes to be reversibly accessible for ion storage. Electrodes constructed from the same material and with the same specifications, which differ only in terms of dimensions and geometries of the constituent particles, can show surprising differences in polarization, stress accumulation and capacity fade. Here, using operando synchrotron X-ray diffraction and energy dispersive X-ray diffraction (EDXRD), we probe the mechanistic origins of the remarkable particle geometry-dependent modification of lithiation-induced phase transformations in V2O5 as a model phase-transforming cathode. A pronounced modulation of phase coexistence regimes is observed as a function of particle geometry. Specifically, a metastable phase is stabilized for nanometre-sized spherical V2O5 particles, to circumvent the formation of large misfit strains. Spatially resolved EDXRD measurements demonstrate that particle geometries strongly modify the tortuosity of the porous cathode architecture. Greater ion-transport limitations in electrode architectures comprising micrometre-sized platelets result in considerable lithiation heterogeneities across the thickness of the electrode. These insights establish particle geometry-dependent modification of metastable phase regimes and electrode tortuosity as key design principles for realizing the promise of intercalation cathodes.

Influence of Potassium Metal-Support Interactions on Dendrite Growth.

Combined synchrotron X-ray nanotomography imaging, cryogenic electron microscopy (cryo-EM) and modeling elucidate how potassium (K) metal-support energetics influence electrodeposit microstructure. Three model supports are employed: O-functionalized carbon cloth (potassiophilic, fully-wetted), non-functionalized cloth and Cu foil (potassiophobic, nonwetted). Nanotomography and focused ion beam (cryo-FIB) cross-sections yield complementary three-dimensional (3D) maps of cycled electrodeposits. Electrodeposit on potassiophobic support is a triphasic sponge, with fibrous dendrites covered by solid electrolyte interphase (SEI) and interspersed with nanopores (sub-10 nm to 100 nm scale). Lage cracks and voids are also a key feature. On potassiophilic support, the deposit is dense and pore-free, with uniform surface and SEI morphology. Mesoscale modeling captures the critical role of substrate-metal interaction on K metal film nucleation and growth, as well as the associated stress state.

Linking void and interphase evolution to electrochemistry in solid-state batteries using operando X-ray tomography.

Despite progress in solid-state battery engineering, our understanding of the chemo-mechanical phenomena that govern electrochemical behaviour and stability at solid-solid interfaces remains limited compared to at solid-liquid interfaces. Here, we use operando synchrotron X-ray computed microtomography to investigate the evolution of lithium/solid-state electrolyte interfaces during battery cycling, revealing how the complex interplay among void formation, interphase growth and volumetric changes determines cell behaviour. Void formation during lithium stripping is directly visualized in symmetric cells, and the loss of contact that drives current constriction at the interface between lithium and the solid-state electrolyte (Li10SnP2S12) is quantified and found to be the primary cause of cell failure. The interphase is found to be redox-active upon charge, and global volume changes occur owing to partial molar volume mismatches at either electrode. These results provide insight into how chemo-mechanical phenomena can affect cell performance, thus facilitating the development of solid-state batteries.

Chemomechanical Interactions Dictate Lithium Surface Diffusion Kinetics in the Solid Electrolyte Interphase.

The solid electrolyte interphase (SEI) plays a pivotal role in enabling fast ionic transport and preserving the battery electrodes from parasitic reactions with solvents. However, due to large volume changes of lithium (Li) electrodes, the SEI layer can potentially undergo mechanical failure, resulting in electrolyte degradation. The mechanical stability of the SEI is a critical aspect that needs to be modulated for designing rechargeable metal batteries with optimal performance. In this work, we perform density functional theory calculations to investigate the mechanical properties of lithium fluoride (LiF) and lithium oxide (Li2O) nanofilms and quantify the Li surface diffusion kinetics over these two SEI materials. Based on our analysis, it is identified that Young's modulus and the ideal strength of the SEI are strong functions of the nanofilm thickness and crystallographic direction. Interestingly, we find that mechanical strain substantially alters the Li surface diffusion behavior on the SEI. For a strain of 4%, while the Li surface diffusion rate decreases by two orders of magnitude on the stretched Li2O film, it increases two times on the stretched LiF film, indicating critical implications on the morphological stability of the metal anode. A fundamental correlation between inherent SEI properties and Li plating behavior is revealed, suggesting a potential pathway to achieve dendrite-free electrodeposition via SEI modulation.

Mechanistic Underpinnings of Morphology Transition in Electrodeposition under the Application of Pulsatile Potential.

We quantitatively investigate the role of voltage fluctuation in terms of different waveforms on the electrodeposition dynamics and morphology for varying electrolyte concentrations. Dependent on the electrolyte concentration, a wide range of morphologies ranging from highly branched dendrites to comparatively closed packed electrodeposits has been captured. We mechanistically map the deposition dynamics by image analysis and demonstrate the highly porous dendritic dynamics to be independent of external perturbation. Additionally, comparatively closed packed morphological features show significant sensitivity toward the frequency and nature of the waveforms. The results provide fundamental insights into the correlation between the time scales of voltage fluctuation and growth dynamics. We comprehensively analyze the effect of the waveform nature on the average deposition height and show sinusoidal fluctuation to be preferred over square and pulse for metal batteries for lower deposition heights.

Tuning the Splitting Behavior of Droplet in a Bifurcating Channel through Wettability-Capillarity Interaction.

We present a comprehensive computational physics-based study of the influence of surface wettability on the displacement behavior of a droplet in a three-dimensional bifurcating channel. Various surface wettability configurations for the daughter branches are considered to gain insight into the wettability-capillarity interaction. Also, the influence of initial droplet size on the splitting dynamics for different wettability configurations is investigated. Time evolution of the droplet displacement behavior in the bifurcating channel is discussed for different physicochemical parameters including capillary number and wettability. Three distinct flow regimes are identified as the droplet interacts with the bifurcating tip of the channel, namely, splitting, nonsplitting, and oscillating regimes. Furthermore, the occurrence of Rayleigh-Plateau instability in different wettability scenarios is discussed. Additionally, the intricacies associated with the droplet dynamics are elucidated through the temporal evolution of the droplet surface area and mass outflow of the continuous phase. A flow regime map based on the capillary number and wettability contrast of the daughter branches is proposed for a comprehensive description of the droplet dynamics.

Surface diffusion manifestation in electrodeposition of metal anodes.

Metal anode-based battery systems have been deemed indispensable towards energy storage renaissance engendering extensive research into strategies countering dendritic growth of metal electrodeposition. Fundamentally, the morphological evolution of a material is uniquely characterized by the heights of its self-diffusion barrier across multiple pathways. Herein, based on a coarse-grained kinetic Monte Carlo method, we derive insights into the nucleation and growth of metallic electrodeposits in liquid electrolytes, governed by surface self-diffusion characteristics cognizant of the diverse diffusion routes including terrace, away from step and interlayer pathways. We deconvolve the roles played by each of these surface diffusion mechanisms in conjunction with the electrochemical reaction rate on the deposition morphology regime (film vs. mossy vs. fractal). We identify interlayer diffusion as the predominant morphology-determining mechanism; dendrite-free deposition even at moderate current rates constrains this diffusion barrier to an upper limit. Additionally, we highlight subtle features amidst the realm of the morphological growth assortment that connect to the cell's electrochemical performance. Finally, we delineate morphological features of Li, Na, Mg and Al based on their respective surface diffusion barriers and applied overpotentials, and provide a baseline for the interpretation of experimental observations. This fundamental study sheds light on the mesoscale underpinnings of morphological variances in mono-valent and multi-valent metal electrodeposition.

Probing spatial coupling of resistive modes in porous intercalation electrodes through impedance spectroscopy.

In porous intercalation electrodes, coupled charge and species transport interactions take place at the pore-scale, while often observations are made at the electrode-scale. The physical manifestation of these interactions from pore- to electrode-scale is poorly understood. Moreover, the spatial arrangement of the constituent material phases forming a porous electrode significantly affects the multi-modal electrochemical and transport interplay. In this study, the relation between the electrode specification, resultant porous microstructure, and electrode-scale resistances is delineated based on a virtual deconvolution of the impedance response. Relevant short- and long-range interactions are identified. Without altering the microstructural arrangement, if the electrode thickness is increased, the resistances do not scale linearly with thickness. This dependence is also probed to identify the fundamental origins of thick electrode limitations.

Revealing reaction mechanisms of nanoconfined Li2S: implications for lithium-sulfur batteries.

Using Li2S as an active material and designing nanostructured cathode hosts are considered as promising strategies to improve the performance of lithium-sulfur (Li-S) batteries. In this study, the reaction mechanisms during the delithiation of nanoconfined Li2S as an active material, represented by a Li20S10 cluster, are examined by first-principles based calculations and analysis. Local reduction and disproportionation reactions can be observed although the overall delithiation process is an oxidation reaction. Long-chain polysulfides can form as intermediate products; however they may bind to insoluble S2-via Li atoms as mediators. Activating the charging process only requires an overpotential of 0.37 V if using Li20S10 as the active material. Sulfur allotropes longer than cyclo-S8 are observed at the end of the charge process. Although the discharge voltage of Li20S10 is only 1.27 V, it can still deliver an appreciable theoretical energy density of 1480 W h kg-1. This study also suggests that hole polarons, in Li20S10 and intermediate products, can serve as carriers to facilitate charge transport. This work provides new insights toward revealing the detailed reaction mechanisms of nanoconfined Li2S as an active material in the Li-S battery cathode.

Evaporation induced nanoparticle - binder interaction in electrode film formation.

Processing induced nanoparticle agglomeration and binder distribution affect the electrode microstructure formation and corresponding electrochemical performance in lithium-ion batteries. In the present study, stochastic dynamics computations based on a morphologically detailed mesoscale model are performed to illustrate the microstructural variability of electrode films affected by the evaporation condition (drying temperature) and the binder length (molecular weight). Micropores are observed at the surface of the electrode film when dried at a lower temperature. The pore formation depth tends to increase as the binder length increases. The solvent chemical potential also affects the surface topography of the electrode film. The solvent with higher volatility (more negative chemical potential) tends to produce more micropores. A lower drying temperature is beneficial for improving the electronic conductivity of the porous electrode film due to the better distribution of the conductive additive nanoparticles on and around the active particles, thereby facilitating the electron transport network formation. Agglomeration between active material nanoparticles can also be mitigated at a lower drying temperature. Additionally, better adhesion of the porous electrode film can be achieved due to preferential localization of the binder on the substrate at relatively low-temperature evaporation.

Probing the morphological influence on solid electrolyte interphase and impedance response in intercalation electrodes.

Solid electrolyte interphase (SEI) formation, due to the electrochemical reaction between the salt and solvent in the electrolyte, is a key contributor to the electrode performance decay in lithium-ion batteries. The active particle morphology and electrode microstructure affect the side reaction rate and hence the SEI induced interfacial transport and impedance behavior. The change resistance due to the variation of SEI thickness can be inferred from electrochemical impedance spectroscopy. In this study, we proposed a microstructure-aware impedance model to predict the effect of electrode microstructure on impedance response. Our model successfully captures the influence of active particle morphology on the SEI formation and corresponding impedance characteristics. Different electrode realizations with microstructural and compositional variations have been considered. The critical influence of active material morphology, mean particle size, binder and electrolyte volume fractions on the SEI formation and impedance behavior reveals the underlying interdependences of the interfacial and transport resistance modes.

Adsorption of insoluble polysulfides Li2S(x) (x = 1, 2) on Li2S surfaces.

In lithium-sulfur batteries, the growth of insulating discharge product Li2S film affects the cathode microstructure and the related electron as well as lithium ion transport properties. In this study, chemical reactions of insoluble lithium polysulfides Li2Sx (x = 1, 2) on crystal Li2S substrate are investigated by a first-principles approach. First-principles atomistic thermodynamics predicts that the stoichiometric (111) and (110) surfaces are stable around the operating cell voltage. Li2Sx adsorption is an exothermic reaction with the (110) surface being more active to react with the polysulfides than the stoichiometric (111) surface. There is no obvious charge transfer between the adsorbed molecule and the crystal Li2S substrate. Analysis of the charge density difference suggests that the adsorbate interacts with the substrate via a strong covalent bond. The growth mechanism of thermodynamically stable surfaces is investigated in the present study. It is found that direct Li2S deposition is energetically favored over Li2S2 deposition and reduction process.

Mesoscale elucidation of the influence of mixing sequence in electrode processing.

Mixing sequence during electrode processing affects the internal microstructure and resultant performance of a lithium-ion battery. In order to fundamentally understand the microstructure evolution during electrode processing, a mesoscale model is presented, which investigates the influence of mixing sequence for different evaporation conditions. Our results demonstrate that a stepwise mixing sequence can produce larger conductive interfacial area ratios than that via a one-step mixing sequence. Small-sized cubical nanoparticles are beneficial for achieving a high conductive interfacial area ratio when a stepwise mixing sequence is employed. Two variants of multistep mixing have been investigated with constant temperature and linearly increasing temperature conditions. It is found that the temperature condition does not significantly affect the conductive interfacial area ratio. The homogeneity of binder distribution in the electrode is also studied, which plays an important role along with the solvent evaporation condition. This study suggests that an appropriate combination of mixing sequence and active particle size and morphology plays a critical role in the formation of electrode microstructures with improved performance.

Electrodeposition Stability Landscape for Solid-Solid Interfaces.

As solid-state batteries (SSBs) with lithium (Li) metal anodes gain increasing traction as promising next-generation energy storage systems, a fundamental understanding of coupled electro-chemo-mechanical interactions is essential to design stable solid-solid interfaces. Notably, uneven electrodeposition at the Li metal/solid electrolyte (SE) interface arising from intrinsic electrochemical and mechanical heterogeneities remains a significant challenge. In this work, the thermodynamic origins of mechanics-coupled reaction kinetics at the Li/SE interface are investigated and its implications on electrodeposition stability are unveiled. It is established that the mechanics-driven energetic contribution to the free energy landscape of the Li deposition/dissolution redox reaction has a critical influence on the interface stability. The study presents the competing effects of mechanical and electrical overpotential on the reaction distribution, and demarcates the regimes under which stress interactions can be tailored to enable stable electrodeposition. It is revealed that different degrees of mechanics contribution to the forward (dissolution) and backward (deposition) reaction rates result in widely varying stability regimes, and the mechanics-coupled kinetics scenario exhibited by the Li/SE interface is shown to depend strongly on the thermodynamic and mechanical properties of the SE. This work highlights the importance of discerning the underpinning nature of electro-chemo-mechanical coupling toward achieving stable solid/solid interfaces in SSBs.

Heterogeneous Solid Electrolyte Interphase Interactions Dictate Interface Instability in Sodium Metal Electrodes.

Sodium (Na) metal batteries have attracted recent attention due to their low cost and high abundance of Na. However, the advancement of Na metal batteries is impeded due to key challenges such as dendrite growth, solid electrolyte interphase (SEI) fracture, and low Coulombic efficiency. This study examines the coupled electro-chemo-mechanical interactions governing the electrodeposition stability and morphological evolution at the Na/electrolyte interface. The SEI heterogeneities influence transport and reaction kinetics leading to the formation of current and stress hotspots during Na plating. Further, it is demonstrated that the heterogeneity-induced Na metal evolution and its influence on the stress distribution critically affect the mechanical overpotential, contributing to a faster SEI failure. The analysis reveals three distinct failure mechanisms-mechanical, transport, and kinetic-that govern the onset of instabilities at the interface. Finally, a comprehensive comparative study of SEI failure in Na and lithium (Li) metal anodes illustrates that the electrochemical and mechanical characteristics of the SEI are crucial in tailoring the anode morphology and interface stability. This work delineates mechanistic stability regimes cognizant of the SEI attributes and underlying failure modes and offers important guidelines for the design of artificial SEI layers for stable Na metal electrodes.

Lithium Plating Characteristics in High Areal Capacity Li-Ion Battery Electrodes.

Li-ion battery degradation and safety events are often attributed to undesirable metallic lithium plating. Since their release, Li-ion battery electrodes have been made progressively thicker to provide a higher energy density. However, the propensity for plating in these thicker pairings is not well understood. Herein, we combine an experimental plating-prone condition with robust mesoscale modeling to examine electrode pairings with capacities ranging from 2.5 to 6 mAh/cm2 and negative to positive (N/P) electrode areal capacity ratio from 0.9 to 1.8 without the need for extensive aging tests. Using both experimentation and a mesoscale model, we identify a shift from conventional high state-of-charge (SOC) type plating to high overpotential (OP) type plating as electrode thickness increases. These two plating modes have distinct morphologies, identified by optical microscopy and electrochemical signatures. We demonstrate that under operating conditions where these plating modes converge, a high propensity of plating exists, revealing the importance of predicting and avoiding this overlap for a given electrode pairing. Further, we identify that thicker electrodes, beyond a capacity of 3 mAh/cm2 or thickness >75 µm, are prone to high OP, limiting negative electrode (NE) utilization and preventing cross-sectional oversizing the NE from mitigating plating. Here, it simply contributes to added mass and volume. The experimental thermal gradient and mesoscale model either combined or independently provide techniques capable of probing performance and safety implications of mild changes to electrode design features.

Electrode-electrolyte interactions dictate thermal stability of sodium-ion batteries.

This work delineates the thermal safety of full-scale sodium-ion batteries (SIBs) by interrogating the material-level electrochemical and thermal responses of micro and nano-structured tin (Sn) based anodes and sodium vanadium phosphate (NVP) cathodes in suitable electrolyte systems. Informed by these material-level signatures, we delineate cell-level thermal safety maps cognizant of underlying electrode-electrolyte interactions in SIBs.