Elucidating and Mitigating High-Voltage Degradation Cascades in Cobalt-Free LiNiO2 Lithium-Ion Battery Cathodes

Operando Building of a Superior Interface Hybrid Film Enables Chemomechanically Durable Co-Free Ni-Rich Cathodes

The Co-free Ni-rich layered cathodes become pivotal to reduce cost and increase benefit toward next-generation Li-ion batteries yet raise a major challenge for their extremely fragile cathode-electrolyte interface (CEI) film. Herein, we report the in situ construction of the Si/B-enriched organic-inorganic hybrid CEI films on LiNi0.9Mn0.1O2 (NM91) with the assistance of tris(trimethylsilyl) borate (TMSB) additive. The hybrid film exhibits superior Young's modulus, mechanical strength, and ductility, which greatly dissipate the microstrain of Co-free Ni-rich cathodes under various states of charge with high structural integrity. Furthermore, the surface oxygen anions have been significantly stabilized by bonding with the Si and B ions of TMSB with high safety. These merits enable a durable Co-free Ni-rich layered cathode with 96.9% and 87.7% capacity retentions (versus 72.7% and 70.2% of NM91) at a high rate of 5C and a high-temperature of 55 °C after 100 cycles. In a pouch-type full cell, 88.8% of initial capacity is still maintained after cycling at 1C for 500 times, greatly expediting the development and application of Co-free Ni-rich layered cathodes.

In Situ Insights into Cathode Calcination for Predictive Synthesis: Kinetic Crystallization of LiNiO2 from Hydroxides

Calcination is a solid-state synthesis process widely deployed in battery cathode manufacturing. However, its inherent complexity associated with elusive intermediates hinders the predictive synthesis of high-performance cathode materials. Here, correlative in situ X-ray absorption/scattering spectroscopy is used to investigate the calcination of nickel-based cathodes, focusing specifically on the archetypal LiNiO2 from Ni(OH)2. Combining in situ observation with data-driven analysis reveals concurrent lithiation and dehydration of Ni(OH)2 and consequently, the low-temperature crystallization of layered LiNiO2 alongside lithiated rocksalts. Following early nucleation, LiNiO2 undergoes sluggish crystallization and structural ordering while depleting rocksalts; ultimately, it turns into a structurally-ordered layered phase upon full lithiation but remains small in size. Subsequent high-temperature sintering induces rapid crystal growth, accompanied by undesired delithiation and structural degradation. These observations are further corroborated by mesoscale modeling, emphasizing that, even though calcination is thermally driven and favors transformation towards thermodynamically equilibrium phases, the actual phase propagation and crystallization can be kinetically tuned via lithiation, providing freedom for structural and morphological control during cathode calcination.

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.

Oxygen vacancy chemistry in oxide cathodes

Secondary batteries are a core technology for clean energy storage and conversion systems, to reduce environmental pollution and alleviate the energy crisis. Oxide cathodes play a vital role in revolutionizing battery technology due to their high capacity and voltage for oxide-based batteries. However, oxygen vacancies (OVs) are an essential type of defect that exist predominantly in both the bulk and surface regions of transition metal (TM) oxide batteries, and have a crucial impact on battery performance. This paper reviews previous studies from the past few decades that have investigated the intrinsic and anionic redox-mediated OVs in the field of secondary batteries. We focus on discussing the formation and evolution of these OVs from both thermodynamic and kinetic perspectives, as well as their impact on the thermodynamic and kinetic properties of oxide cathodes. Finally, we offer insights into the utilization of OVs to enhance the energy density and lifespan of batteries. We expect that this review will advance our understanding of the role of OVs and subsequently boost the development of high-performance electrode materials for next-generation energy storage devices.

Cobalt-free composite-structured cathodes with lithium-stoichiometry control for sustainable lithium-ion batteries

Lithium-ion batteries play a crucial role in decarbonizing transportation and power grids, but their reliance on high-cost, earth-scarce cobalt in the commonly employed high-energy layered Li(NiMnCo)O2 cathodes raises supply-chain and sustainability concerns. Despite numerous attempts to address this challenge, eliminating Co from Li(NiMnCo)O2 remains elusive, as doing so detrimentally affects its layering and cycling stability. Here, we report on the rational stoichiometry control in synthesizing Li-deficient composite-structured LiNi0.95Mn0.05O2, comprising intergrown layered and rocksalt phases, which outperforms traditional layered counterparts. Through multiscale-correlated experimental characterization and computational modeling on the calcination process, we unveil the role of Li-deficiency in suppressing the rocksalt-to-layered phase transformation and crystal growth, leading to small-sized composites with the desired low anisotropic lattice expansion/contraction during charging and discharging. As a consequence, Li-deficient LiNi0.95Mn0.05O2 delivers 90% first-cycle Coulombic efficiency, 90% capacity retention, and close-to-zero voltage fade for 100 deep cycles, showing its potential as a Co-free cathode for sustainable Li-ion batteries.

Oxygen Loss on Disordered Li-Excess, Mn-Rich Li-Ion Cathode Li2MnO2F through First-Principles Modeling

Oxygen evolution energies were calculated for the {100}, {110}, {111}, and {112} type facets of the rock-salt-structured cation-disordered Li-excess, Mn-rich Li-ion (DRX) cathode Li2MnO2F at the fully lithiated, 25% delithiation, and 50% delithiation states. Our calculations showed that Li2MnO2F remains much more robust to O loss than its nonfluorinated counterparts, as has been shown in experimental work. In particular, the {110} and {112} facets are the most resilient against O loss. Focusing on the {100} type facet, which previous work has shown to be the most likely exposed facet of Li2MnO2F, it was found that higher proportions of Li in an O coordination shell lead to lower O evolution energy (ẼO) and facilitate O loss. It was also found that at higher states of delithiation, surface fluorine had a weaker effect in increasing ẼO, meaning the protective effect of F against O loss is more effective at higher lithiation states. Electronic structure chemical bonding analysis revealed weaker bonding interactions between Li and O correlated with lower ẼO and hence a higher propensity for surface O loss..

Stacking Fault Formation in LiNi0.6Co0.2Mn0.2O2 during Cycling: Fundamental Insights into the Direct Recycling of Spent Lithium-Ion Batteries

As the global marketplace for lithium-ion batteries (LIBs) proliferates, technologies for efficient and environmentally friendly recycling, i.e., direct recycling, of spent LIBs are urgently required. In this contribution, we elucidated the mechanisms underlying the degradation that occurs during the cycling of a Li/LiNi0.6Co0.2Mn0.2O2 (NCM622) cell. The results provided fundamental insights into the optimum procedures for direct recycling using a recently developed, state-of-the-art positive electrode material. Capacity fade in NCM622 was induced by cycling at high voltages above 4.6 V vs Li+/Li, during which the rhombohedral symmetry approached cubic symmetry. The selective line broadening and peak shifts that appeared in the X-ray diffraction patterns after cycling indicated the formation of stacking faults along the ch-axis. In addition, high-resolution transmission electron microscopy clarified that rock-salt domains were located on the NCM622 surface before and after cycling. These structural analyses confirmed that the NCM622 particles degrade not at their surfaces but rather in the bulk, contradicting previous reports where degradation during cycling is mainly caused by rock-salt domains on the surface. Material regeneration processes involving the restoration of the original stacking sequence are essential for effective direct recycling.

Electrolyte Coatings for High Adhesion Interfaces in Solid-State Batteries from First Principles

We introduce an adhesion parameter that enables rapid screening for materials interfaces with high adhesion. This parameter is obtained by density functional theory calculations of individual single-material slabs rather than slabs consisting of combinations of two materials, eliminating the need to calculate all configurations of a prohibitively vast space of possible interface configurations. Cleavage energy calculations are used as an upper bound for electrolyte and coating energies and implemented in an adapted contact angle equation to derive the adhesion parameter. In addition to good adhesion, we impose further constraints in electrochemical stability window, abundance, bulk reactivity, and stability to screen for coating materials for next-generation solid-state batteries. Good adhesion is critical in combating delamination and resistance to lithium diffusivity in solid-state batteries. Here, we identify several promising coating candidates for the Li7La3Zr2O12 and sulfide electrolyte systems including the previously investigated electrode coating materials LiAlSiO4 and Li5AlO8, making them especially attractive for experimental optimization and commercialization.

Building Practical High-Voltage Cathode Materials for Lithium-Ion Batteries

It has long been a global imperative to develop high-energy-density lithium-ion batteries (LIBs) to meet the ever-growing electric vehicle market. One of the most effective strategies for boosting the energy density of LIBs is to increase the output voltage, which largely depends upon the cathode materials. As the most-promising cathodes for high-voltage LIBs (>4 V vs Li/Li⁺ ), four major categories of cathodes including lithium-rich layered oxides, nickel-rich layered oxides, spinel oxides, and high-voltage polyanionic compounds still encounter severe challenges to realize the improvement of output voltage while maintaining high capacity, fast rate capability, and long service life. This review focuses on the key links in the development of high-voltage cathode materials from the lab to industrialization. First, the failure mechanisms of the four kinds of materials are clarified, and the optimization strategies, particularly solutions that are easy for large-scale production, are considered. Then, to bridge the gap between lab and industry, the cost management, safety assessment, practical battery-performance evaluation, and sustainability of the battery technologies, are discussed. Finally, tough challenges and promising strategies for the commercialization of high-voltage cathode materials are summarized to promote the large-scale application of LIBs with high energy densities.

Advancing to 4.6 V Review and Prospect in Developing High-Energy-Density LiCoO2 Cathode for Lithium-Ion Batteries

Layered LiCoO₂ (LCO) is one of the most important cathodes for portable electronic products at present and in the foreseeable future. It becomes a continuous push to increase the cutoff voltage of LCO so that a higher capacity can be achieved, for example, a capacity of 220 mAh g^-1 at 4.6 V compared to 175 mAh g^-1 at 4.45 V, which is unfortunately accompanied by severe capacity degradation due to the much-aggravated side reactions and irreversible phase transitions. Accordingly, strict control on the LCO becomes essential to combat the inherent instability related to the high voltage challenge for their future applications. This review begins with a discussion on the relationship between the crystal structures and electrochemical properties of LCO as well as the failure mechanisms at 4.6 V. Then, recent advances in control strategies for 4.6 V LCO are summarized with focus on both bulk structure and surface properties. One closes this review by presenting the outlook for future efforts on LCO-based lithium ion batteries (LIBs). It is hoped that this work can draw a clear map on the research status of 4.6 V LCO, and also shed light on the future directions of materials design for high energy LIBs.

High-Voltage Induced Surface and Intragranular Structural Evolution of Ni-Rich Layered Cathode

Layered Ni-rich lithium transition metal oxides are promising cathode materials for high-energy-density lithium-ion batteries. These cathodes, however, suffer from rapid performance decay under high-voltage operation. In this work, the electrochemical properties and structural evolution of the LiNi_0.8 Mn_0.1 Co_0.1 O₂ (NMC811) cathode upon high-voltage cycling are investigated. The results show that the NMC811 cathode not only experiences surface evolution with the formation of Li-deficient rock-salt layers, but also suffers from drastic intragranular structural changes inside bulk grains after high-voltage cycling. Direct evidence for the formation of transition-metal/Li disordering domains with uneven Li content and lattice plane distortion at the internal grains of 4.6 V-cycled NMC811 are provided with their atomic ordering and spatial distribution clearly resolved. The complex intragranular structural changes impede Li⁺ diffusion inside bulk material, resulting in kinetic limitation and capacity loss. The results demonstrate that the high-voltage cycling would induce severe structural degradation at the grain interior of the cathode material beyond surface evolution, which contributes significantly to the rapid performance decay of the NMC811 cathode. The findings provide new insights for developing effective countermeasures to mitigate this degradation pathway.

Stability Optimization Strategies of Cathode Materials for Aqueous Zinc Ion Batteries: A Mini Review

Among the new energy storage devices, aqueous zinc ion batteries (AZIBs) have become the current research hot spot with significant advantages of low cost, high safety, and environmental protection. However, the cycle stability of cathode materials is unsatisfactory, which leads to great obstacles in the practical application of AZIBs. In recent years, a large number of studies have been carried out systematically and deeply around the optimization strategy of cathode material stability of AZIBs. In this review, the factors of cyclic stability attenuation of cathode materials and the strategies of optimizing the stability of cathode materials for AZIBs by vacancy, doping, object modification, and combination engineering were summarized. In addition, the mechanism and applicable material system of relevant optimization strategies were put forward, and finally, the future research direction was proposed in this article.