Spatially Resolving Lithiation in Silicon-Graphite Composite Electrodes via in Situ High-Energy X-ray Diffraction Computed Tomography

Recent developments in X-ray diffraction/scattering computed tomography for materials science

X-ray diffraction/scattering computed tomography (XDS-CT) methods are a non-destructive class of chemical imaging techniques that have the capacity to provide reconstructions of sample cross-sections with spatially resolved chemical information. While X-ray diffraction CT (XRD-CT) is the most well-established method, recent advances in instrumentation and data reconstruction have seen greater use of related techniques like small angle X-ray scattering CT and pair distribution function CT. Additionally, the adoption of machine learning techniques for tomographic reconstruction and data analysis are fundamentally disrupting how XDS-CT data is processed. The following narrative review highlights recent developments and applications of XDS-CT with a focus on studies in the last five years. This article is part of the theme issue 'Exploring the length scales, timescales and chemistry of challenging materials (Part 2)'.

Large Local Currents in a Lithium-Ion Battery during Rest after Fast Charging

Increasing electric vehicle (EV) adoption requires lithium-ion batteries that can be charged quickly and safely. Some EV batteries have caught on fire despite being neither charged nor discharged. While the lithium that plates on graphite during fast charging affects battery safety, so do the internal ionic currents that can occur when the battery is at rest after charging. These currents are difficult to quantify; the external current that can readily be measured is zero. Here we study a graphite electrode at rest after 6C fast charging using operando X-ray microtomography. We quantify spatially resolved current density distributions that originate at plated lithium and end in underlithiated graphite particles. The average current densities decrease from 1.5 to 0.5 mA cm-2 in about 20 min after charging is stopped. Surprisingly, the range of the stripping current density is independent of time, with outliers above 20 mA cm-2. The persistence of outliers provides a clue as to the origin of catastrophic failure in batteries at rest.

Mapping internal temperatures during high-rate battery applications

Electric vehicles demand high charge and discharge rates creating potentially dangerous temperature rises. Lithium-ion cells are sealed during their manufacture, making internal temperatures challenging to probe1. Tracking current collector expansion using X-ray diffraction (XRD) permits non-destructive internal temperature measurements2; however, cylindrical cells are known to experience complex internal strain3,4. Here, we characterize the state of charge, mechanical strain and temperature within lithium-ion 18650 cells operated at high rates (above 3C) by means of two advanced synchrotron XRD methods: first, as entire cross-sectional temperature maps during open-circuit cooling and second, single-point temperatures during charge-discharge cycling. We observed that a 20-minute discharge on an energy-optimized cell (3.5 Ah) resulted in internal temperatures above 70 °C, whereas a faster 12-minute discharge on a power-optimized cell (1.5 Ah) resulted in substantially lower temperatures (below 50 °C). However, when comparing the two cells under the same electrical current, the peak temperatures were similar, for example, a 6 A discharge resulted in 40 °C peak temperatures for both cell types. We observe that the operando temperature rise is due to heat accumulation, strongly influenced by the charging protocol, for example, constant current and/or constant voltage; mechanisms that worsen with cycling because degradation increases the cell resistance. Design mitigations for temperature-related battery issues should now be explored using this new methodology to provide opportunities for improved thermal management during high-rate electric vehicle applications.

Recent Progress in Silicon-Based Materials for Performance-Enhanced Lithium-Ion Batteries

Silicon (Si) has been considered to be one of the most promising anode materials for high energy density lithium-ion batteries (LIBs) due to its high theoretical capacity, low discharge platform, abundant raw materials and environmental friendliness. However, the large volume changes, unstable solid electrolyte interphase (SEI) formation during cycling and intrinsic low conductivity of Si hinder its practical applications. Various modification strategies have been widely developed to enhance the lithium storage properties of Si-based anodes, including cycling stability and rate capabilities. In this review, recent modification methods to suppress structural collapse and electric conductivity are summarized in terms of structural design, oxide complexing and Si alloys, etc. Moreover, other performance enhancement factors, such as pre-lithiation, surface engineering and binders are briefly discussed. The mechanisms behind the performance enhancement of various Si-based composites characterized by in/ex situ techniques are also reviewed. Finally, we briefly highlight the existing challenges and future development prospects of Si-based anode materials.

5D total scattering computed tomography reveals the full reaction mechanism of a bismuth vanadate lithium ion battery anode

We have used operando 5D synchrotron total scattering computed tomography (TSCT) to understand the cycling and possible long term deactivation mechanisms of the lithium-ion battery anode bismuth vanadate. This anode material functions via a combined conversion/alloying mechanism in which nanocrystals of lithium-bismuth alloy are protected by an amorphous matrix of lithium vanadate. This composite is formed in situ during the first lithiation of the anode. The operando TSCT data were analyzed and mapped using both pair distribution function and Rietveld methods. We can follow the lithium-bismuth alloying reaction at all stages, gaining real structural insight including variations in nanoparticle sizes, lattice parameters and bond lengths, even when the material is completely amorphous. We also observe for the first time structural changes related to the cycling of lithium ions in the lithium vanadate matrix, which displays no interactions beyond the first shell of V-O bonds. The first 3D operando mapping of the distribution of different materials in an amorphous anode reveals a decline in coverage caused by either agglomeration or partial dissolution of the active material, hinting at the mechanism of long term deactivation. The observations from the operando experiment are backed up by post mortem transmission electron microscope (TEM) studies and theoretical calculations to provide a complete picture of an exceptionally complex cycling mechanism across a range of length scales.

Computer-Vision-Based Approach to Classify and Quantify Flaws in Li-Ion Electrodes

X-ray computed tomography (X-ray CT) is a non-destructive characterization technique that in recent years has been adopted to study the microstructure of battery electrodes. However, the often manual and laborious data analysis process hinders the extraction of useful metrics that can ultimately inform the mechanisms behind cycle life degradation. This work presents a novel approach that combines two convolutional neural networks to first locate and segment each particle in a nano-CT LiNiMnCoO₂ (NMC) electrode dataset, and successively classifies each particle according to the presence of flaws or cracks within its internal structure. Metrics extracted from the computer vision segmentation are validated with respect to traditional threshold-based segmentation, confirming that flawed particles are correctly identified as single entities. Successively, slices from each particle are analyzed by a pre-trained classifier to detect the presence of flaws or cracks. The models are used to quantify microstructural evolution in uncycled and cycled NMC811 electrodes, as well as the number of flawed particles in a NMC622 electrode. As a proof-of-concept, a 3-phase segmentation is also presented, whereby each individual flaw is segmented as a separate pixel label. It is anticipated that this analysis pipeline will be widely used in the field of battery research and beyond.

Highly Enforced Rate Capability of a Graphite Anode via Interphase Chemistry Tailoring Based on an Electrolyte Additive

The rate capability of lithium-ion batteries is highly dependent on the interphase chemistry of graphite anodes. Herein, we demonstrate an anode interphase tailoring based on a novel electrolyte additive, lithium dodecyl sulfate (LiDS), which greatly improves the rate capability and cyclic stability of graphite anodes. Upon application of 1% LiDS in a base electrolyte, the discharge capacity at 2 C is improved from 102 to 240 mAh g-1 and its capacity retention is enhanced from 51% to 94% after 200 cycles at 0.5 C. These excellent performances are attributed to the preferential absorption of LiDS and the as-constructed interphase chemistry that is mainly composed of organic long-chain polyether and inorganic lithium sulfite. The long-chain polyether possesses flexibility endowing the interphase with robustness, while its combination with inorganic lithium sulfite accelerates lithium intercalation/deintercalation kinetics via decreasing the resistance for charge transfer.

Bridging nano- and microscale X-ray tomography for battery research by leveraging artificial intelligence

X-ray computed tomography (CT) is a non-destructive imaging technique in which contrast originates from the materials' absorption coefficient. The recent development of laboratory nanoscale CT (nano-CT) systems has pushed the spatial resolution for battery material imaging to voxel sizes of 50 nm, a limit previously achievable only with synchrotron facilities. Given the non-destructive nature of CT, in situ and operando studies have emerged as powerful methods to quantify morphological parameters, such as tortuosity factor, porosity, surface area and volume expansion, during battery operation or cycling. Combined with artificial intelligence and machine learning analysis techniques, nano-CT has enabled the development of predictive models to analyse the impact of the electrode microstructure on cell performances or the influence of material heterogeneities on electrochemical responses. In this Review, we discuss the role of X-ray CT and nano-CT experimentation in the battery field, discuss the incorporation of artificial intelligence and machine learning analyses and provide a perspective on how the combination of multiscale CT imaging techniques can expand the development of predictive multiscale battery behavioural models.

Probing the Role of Multi-scale Heterogeneity in Graphite Electrodes for Extreme Fast Charging

Electrode-scale heterogeneity can combine with complex electrochemical interactions to impede lithium-ion battery performance, particularly during fast charging. This study investigates the influence of electrode heterogeneity at different scales on the lithium-ion battery electrochemical performance under operational extremes. We employ image-based mesoscale simulation in conjunction with a three-dimensional electrochemical model to predict performance variability in 14 graphite electrode X-ray computed tomography data sets. Our analysis reveals that the tortuous anisotropy stemming from the variable particle morphology has a dominating influence on the overall cell performance. Cells with platelet morphology achieve lower capacity, higher heat generation rates, and severe plating under extreme fast charge conditions. On the contrary, the heterogeneity due to the active material clustering alone has minimal impact. Our work suggests that manufacturing electrodes with more homogeneous and isotropic particle morphology will improve electrochemical performance and improve safety, enabling electromobility.

Microscale Silicon-Based Anodes: Fundamental Understanding and Industrial Prospects for Practical High-Energy Lithium-Ion Batteries

To accelerate the commercial implementation of high-energy batteries, recent research thrusts have turned to the practicality of Si-based electrodes. Although numerous nanostructured Si-based materials with exceptional performance have been reported in the past 20 years, the practical development of high-energy Si-based batteries has been beset by the bias between industrial application with gravimetrical energy shortages and scientific research with volumetric limits. In this context, the microscale design of Si-based anodes with densified microstructure has been deemed as an impactful solution to tackle these critical issues. However, their large-scale application is plagued by inadequate cycling stability. In this review, we present the challenges in Si-based materials design and draw a realistic picture regarding practical electrode engineering. Critical appraisals of recent advances in microscale design of stable Si-based materials are presented, including interfacial tailoring of Si microscale electrode, surface modification of SiO_x microscale electrode, and structural engineering of hierarchical microscale electrode. Thereafter, other practical metrics beyond active material are also explored, such as robust binder design, electrolyte exploration, prelithiation technology, and thick-electrode engineering. Finally, we provide a roadmap starting with material design and ending with the remaining challenges and integrated improvement strategies toward Si-based full cells.

Cycling Rate-Induced Spatially-Resolved Heterogeneities in Commercial Cylindrical Li-Ion Batteries

Synchrotron high-energy X-ray diffraction computed tomography has been employed to investigate, for the first time, commercial cylindrical Li-ion batteries electrochemically cycled over the two cycling rates of C/2 and C/20. This technique yields maps of the crystalline components and chemical species as a cross-section of the cell with high spatiotemporal resolution (550 × 550 images with 20 × 20 × 3 µm³ voxel size in ca. 1 h). The recently developed Direct Least-Squares Reconstruction algorithm is used to overcome the well-known parallax problem and led to accurate lattice parameter maps for the device cathode. Chemical heterogeneities are revealed at both electrodes and are attributed to uneven Li and current distributions in the cells. It is shown that this technique has the potential to become an invaluable diagnostic tool for real-world commercial batteries and for their characterization under operating conditions, leading to unique insights into "real" battery degradation mechanisms as they occur.

Synchrotron X-Ray Tomography for Rechargeable Battery Research: Fundamentals, Setups and Applications

Understanding the complicated interplay of the continuously evolving electrode materials in their inherent 3D states during the battery operating condition is of great importance for advancing rechargeable battery research. In this regard, the synchrotron X-ray tomography technique, which enables non-destructive, multi-scale, and 3D imaging of a variety of electrode components before/during/after battery operation, becomes an essential tool to deepen this understanding. The past few years have witnessed an increasingly growing interest in applying this technique in battery research. Hence, it is time to not only summarize the already obtained battery-related knowledge by using this technique, but also to present a fundamental elucidation of this technique to boost future studies in battery research. To this end, this review firstly introduces the fundamental principles and experimental setups of the synchrotron X-ray tomography technique. After that, a user guide to its application in battery research and examples of its applications in research of various types of batteries are presented. The current review ends with a discussion of the future opportunities of this technique for next-generation rechargeable batteries research. It is expected that this review can enhance the reader's understanding of the synchrotron X-ray tomography technique and stimulate new ideas and opportunities in battery research.

3D Detection of Lithiation and Lithium Plating in Graphite Anodes during Fast Charging

A barrier to the widespread adoption of electric vehicles is enabling fast charging lithium-ion batteries. At normal charging rates, lithium ions intercalate into the graphite electrode. At high charging rates, lithiation is inhomogeneous, and metallic lithium can plate on the graphite particles, reducing capacity and causing safety concerns. We have built a cell for conducting high-resolution in situ X-ray microtomography experiments to quantify three-dimensional lithiation inhomogeneity and lithium plating. Our studies reveal an unexpected correlation between these two phenomena. During fast charging, a layer of mossy lithium metal plates at the graphite electrode-separator interface. The transport bottlenecks resulting from this layer lead to underlithiated graphite particles well-removed from the separator, near the current collector. These underlithiated particles lie directly underneath the mossy lithium, suggesting that lithium plating inhibits further lithiation of the underlying electrode.

Powder diffraction computed tomography: a combined synchrotron and neutron study

Diffraction and imaging using x-rays and neutrons are widely utilized in different fields of engineering, biology, chemistry and/or materials science. The additional information gained from the diffraction signal by x-ray diffraction and computed tomography (XRD-CT) can give this method a distinct advantage in materials science applications compared to classical tomography. Its active development over the last decade revealed structural details in a non-destructive way with unprecedented sensitivity. In the current contribution an attempt to adopt the well-established XRD-CT technique for neutron diffraction computed tomography (ND-CT) is reported. A specially designed 'phantom', an object displaying adaptable contrast sufficient for both XRD-CT and ND-CT, was used for method validation. The feasibility of ND-CT is demonstrated, and it is also shown that the ND-CT technique is capable to provide a non-destructive view into the interior of the 'phantom' delivering structural information consistent with a reference XRD-CT experiment.

4D Bragg Edge Tomography of Directional Ice Templated Graphite Electrodes

Bragg edge tomography was carried out on novel, ultra-thick, directional ice templated graphite electrodes for Li-ion battery cells to visualise the distribution of graphite and stable lithiation phases, namely LiC12 and LiC6. The four-dimensional Bragg edge, wavelength-resolved neutron tomography technique allowed the investigation of the crystallographic lithiation states and comparison with the electrode state of charge. The tomographic imaging technique provided insight into the crystallographic changes during de-/lithiation over the electrode thickness by mapping the attenuation curves and Bragg edge parameters with a spatial resolution of approximately 300 µm. This feasibility study was performed on the IMAT beamline at the ISIS pulsed neutron spallation source, UK, and was the first time the 4D Bragg edge tomography method was applied to Li-ion battery electrodes. The utility of the technique was further enhanced by correlation with corresponding X-ray tomography data obtained at the Diamond Light Source, UK.

DLSR: a solution to the parallax artefact in X-ray diffraction computed tomography data

A new tomographic reconstruction algorithm is presented, termed direct least-squares reconstruction (DLSR), which solves the well known parallax problem in X-ray-scattering-based experiments. The parallax artefact arises from relatively large samples where X-rays, scattered from a scattering angle 2θ, arrive at multiple detector elements. This phenomenon leads to loss of physico-chemical information associated with diffraction peak shape and position (i.e. altering the calculated crystallite size and lattice parameter values, respectively) and is currently the major barrier to investigating samples and devices at the centimetre level (scale-up problem). The accuracy of the DLSR algorithm has been tested against simulated and experimental X-ray diffraction computed tomography data using the TOPAS software.

Using In-Situ Laboratory and Synchrotron-Based X-ray Diffraction for Lithium-Ion Batteries Characterization: A Review on Recent Developments

Renewable technologies, and in particular the electric vehicle revolution, have generated tremendous pressure for the improvement of lithium ion battery performance. To meet the increasingly high market demand, challenges include improving the energy density, extending cycle life and enhancing safety. In order to address these issues, a deep understanding of both the physical and chemical changes of battery materials under working conditions is crucial for linking degradation processes to their origins in material properties and their electrochemical signatures. In situ and operando synchrotron-based X-ray techniques provide powerful tools for battery materials research, allowing a deep understanding of structural evolution, redox processes and transport properties during cycling. In this review, in situ synchrotron-based X-ray diffraction methods are discussed in detail with an emphasis on recent advancements in improving the spatial and temporal resolution. The experimental approaches reviewed here include cell designs and materials, as well as beamline experimental setup details. Finally, future challenges and opportunities for battery technologies are discussed.

Synergistic Effect of Nitrogen Doping and Ultra-Microporosity on the Performance of Biomass and Microalgae-Derived Activated Carbons for CO2 Capture

We report a unique naturally derived activated carbon with optimally incorporated nitrogen functional groups and ultra-microporous structure to enable high CO₂ adsorption capacity. The coprocessing of biomass (Citrus aurantium waste leaves) and microalgae (Spirulina) as the N-doping agent was investigated by probing the parameter space (biomass/microalgae weight ratio, reaction temperature, and reaction time) of hydrothermal carbonization and activation process (via the ZnCl₂/CO₂ activation) to generate hydrochars and activated carbons, respectively, with tunable nitrogen content and pore sizes. The central composite-based design of the experiment was applied to optimize the parameters of the prehydrothermal carbonization procedure resulting in the fabrication of N-enriched carbonaceous products with the highest possible mass yield and nitrogen content. The resulting hydrochars and activated carbon samples were characterized using elemental analysis, X-ray diffraction, Fourier transform infrared spectroscopy, X-ray photoelectron spectroscopy, field emission scanning electron microscopy, and Brunauer-Emmett-Teller surface area analysis. We observe that while N-doping and the activation process can individually enhance the CO₂ adsorption capacity to some extent, it is the combined effect of the two processes that synergistically work to greatly increase the adsorption capacity of the N-doped activated carbon by an amount which is more than the sum of individual contributions. We analyze the origins of this synergy with both physical and chemical characterization techniques. The resulting naturally derived activated carbon demonstrates one of the highest CO₂ adsorption capacities (8.43 mmol/g) with rapid adsorption kinetics and good selectivity and reusability.

Exploring cycling induced crystallographic change in NMC with X-ray diffraction computed tomography

This study presents the application of X-ray diffraction computed tomography for the first time to analyze the crystal dimensions of LiNi0.33Mn0.33Co0.33O2 electrodes cycled to 4.2 and 4.7 V in full cells with graphite as negative electrodes at 1 μm spatial resolution to determine the change in unit cell dimensions as a result of electrochemical cycling. The nature of the technique permits the spatial localization of the diffraction information in 3D and mapping of heterogeneities from the electrode to the particle level. An overall decrease of 0.4% and 0.6% was observed for the unit cell volume after 100 cycles for the electrodes cycled to 4.2 and 4.7 V. Additionally, focused ion beam-scanning electron microscope cross-sections indicate extensive particle cracking as a function of upper cut-off voltage, further confirming that severe cycling stresses exacerbate degradation. Finally, the technique facilitates the detection of parts of the electrode that have inhomogeneous lattice parameters that deviate from the bulk of the sample, further highlighting the effectiveness of the technique as a diagnostic tool, bridging the gap between crystal structure and electrochemical performance.

Understanding Protection Mechanisms of Graphene-Encapsulated Silicon Anodes with Operando Raman Spectroscopy

Carbon-coated silicon micro- and nanostructures have been widely used as composite anodes for lithium-ion batteries combining the benefits of high theoretical capacity of Si and better conductivity of carbon. To optimize structures that allow the Si volume expansion without losing the electrical connection, a detailed carbon protection mechanism is desired. We fabricate a network of interconnected sandwich branches with a silicon thin film encapsulated between a porous 3-dimensional graphene foam and graphene drapes (so-called a graphene ensemble). This prototype binder-free anode, of great mechanical strength and composed of only silicon and few-layer graphene, provides distinct signals under operando Raman spectroscopy. During electrochemical cycles, the graphene G peak shows variation of peak position and intensity, while the 2D peak experiences a negligible shift from limited deformation. Silicon displays excellent structural reversibility under the sandwich protection, validating the functions of graphenic carbon coating. This specific graphene ensemble can also serve as an experimental scaffold for mechanical and chemical analysis of many active materials.

Spatial quantification of dynamic inter and intra particle crystallographic heterogeneities within lithium ion electrodes

The performance of lithium ion electrodes is hindered by unfavorable chemical heterogeneities that pre-exist or develop during operation. Time-resolved spatial descriptions are needed to understand the link between such heterogeneities and a cell's performance. Here, operando high-resolution X-ray diffraction-computed tomography is used to spatially and temporally quantify crystallographic heterogeneities within and between particles throughout both fresh and degraded Li_xMn₂O₄ electrodes. This imaging technique facilitates identification of stoichiometric differences between particles and stoichiometric gradients and phase heterogeneities within particles. Through radial quantification of phase fractions, the response of distinct particles to lithiation is found to vary; most particles contain localized regions that transition to rock salt LiMnO₂ within the first cycle. Other particles contain monoclinic Li₂MnO₃ near the surface and almost pure spinel Li_xMn₂O₄ near the core. Following 150 cycles, concentrations of LiMnO₂ and Li₂MnO₃ significantly increase and widely vary between particles.