Synthesis of LiNiO2 at Moderate Oxygen Pressure and Long-Term Cyclability in Lithium-Ion Full Cells

In Situ 4D STEM of LiNiO2 Particles Heated in an Oxygen Atmosphere: Toward Investigation of Solid-State Batteries Under Realistic Processing Conditions

Cathode active material (CAM) particles and solid electrolyte (SE) - CAM composites for solid-state batteries (SSBs) are often subjected to elevated temperatures during annealing or co-sintering. This thermal treatment can affect the material's structure and induce degradation processes, particularly at the SE - CAM interface. To better understand these phenomena and improve material stability and performance, investigations by (scanning) transmission electron microscopy ((S)TEM) under realistic processing conditions, i.e., in an oxygen atmosphere, are desirable. However, preparing electron-transparent TEM lamellae of SE - CAM composites with intact interfaces is highly challenging. Therefore, an in situ heating methodology is first established using LiNiO2 (LNO) particles as a model system. In this study, the morphological and structural evolution of thinned LNO particles during heating in an oxygen atmosphere is investigated, employing in situ 4D nanobeam STEM. The in situ observations are complemented with postmortem electron diffraction and spectroscopy measurements. These findings indicate that LNO undergoes structural degradation at temperatures ≈350 °C, transitioning from the layered (R 3 ¯ m $R\bar 3m$ ) structure to a NiO-type rock-salt phase (F m 3 ¯ m $Fm\bar 3m$ ). This onset temperature is significantly higher than that observed in comparable in situ heating experiments conducted in vacuum, highlighting the importance of an oxygen atmosphere for replicating real-world processing conditions.

A review of Ni-based layered oxide cathode materials for alkali-ion batteries

Compared with the costly and toxic LiCoO2 cathode in lithium-ion batteries (LIBs), nickel-based layered oxide (NLO) cathode materials exhibit the advantages of high capacity, natural abundance, environment-friendliness, and low cost, displaying tremendous application potentials in power batteries for automobiles and aircrafts. This review comprehensively introduces the challenges faced by NLO cathode materials in all alkali-ion batteries (AIBs) in their material synthesis, cation mixing, particle cracking, phase changes, cation dissolution of Mn, and oxygen loss Various strategies, including heteroatom doping, surface coating, and concentration gradient, are applied to tackle these problems by developing layered LiNi1-xMxO2 (M: metal; 0 < x < 1) and LiNixCoyMnzO2 (x + y + z = 1) materials. The successful commercial application of NLO cathode materials in LIBs has further driven their developments in sodium/potassium-ion batteries via the synthesis of (Na/K)Ni1-xMxO2. Moreover, many sophisticated techniques, including in situ X-ray diffraction, scanning/transmission electron microscopy, operando neutron diffraction, and elemental analysis, are used to simultaneously monitor real-time phase changes, lattice variations, structural distortions, and elemental dissolutions of NLO-based materials. Furthermore, density functional theory (DFT) calculations are discussed as a powerful tool for predicting structural evolution, energy band structures, optimal doping concentrations, and ion diffusion pathways, thereby guiding the reasonable design of these materials. Finally, this review provides perspectives on future research directions and modification strategies for NLO cathode materials in AIBs, aiming to accelerate their deployment in electric vehicles and other energy storage devices. These efforts are expected to contribute significantly to the advancement of sustainable energy technologies and the global pursuit for carbon neutrality.

Unlocking the potential of Ni-rich LiNi0.9Co0.1O2 cathodes: a DFT investigation of performance-limiting factors

Ni-rich layered oxides, particularly LiNi0.9Co0.1O2, have garnered significant attention in the realm of high-capacity cathodes for lithium-ion batteries. Despite their promise, their commercialization is hindered by challenges related to structural instability and defect formation. This study utilizes density functional theory (DFT) to unravel the intricate structural, defect formation, and transport properties of LiNi0.9Co0.1O2, thereby providing insights into the performance-limiting factors. Our findings reveal that a 10% cobalt doping while enhancing lithium mobility, is insufficient to significantly mitigate antisite defects and oxygen vacancy formation. These defects are critical in influencing the electrochemical performance and durability of the material. The study further delves into the implications of defect formation on the electrochemical characteristics, emphasizing the need for a higher concentration of cobalt doping to effectively stabilize the Ni-rich cathode. This theoretical investigation contributes to the understanding of defect behaviors in Ni-rich cathodes and paves the way for optimized material design in future high-energy-density battery technologies.

Electrolyte-Enabled High-Voltage Operation of a Low-Nickel, Low-Cobalt Layered Oxide Cathode for High Energy Density Lithium-Ion Batteries

The lithium-ion battery industry acknowledges the need to reduce expensive metals, such as cobalt and nickel, due to supply chain challenges. However, doing so can drastically reduce the overall battery energy density, attenuating the driving range for electric vehicles. Cycling to higher voltages can increase the capacity and energy density but will consequently exacerbate cell degradation due to the instability at high voltages. Herein, an advanced localized high-concentration electrolyte (LHCE) is utilized to enable long-term cycling of a low-Ni, low-Co layered oxide cathode LiNi0.60Mn0.31Co0.07Al0.02O2 (NMCA) in full cells with graphite or graphite-silicon anodes at 4.5 V (≈4.6 vs Li+/Li). NMCA cells with the LHCE deliver a high initial capacity of 194 mA h g-1 at C/10 rate along with 73% capacity retention after 400 cycles compared to 49% retention in a baseline carbonate electrolyte. This is facilitated by reduced impedance growth, active material loss, and gas evolution with the NMCA cathode. These improvements are attributed to the formation of robust, inorganic-rich interphase layers on both the cathode and anode throughout cycling, which are induced by a favorable salt decomposition in the LHCE. This study demonstrates the efficacy of electrolytes toward facilitating the operation of high-energy-density, long-life, and cost-effective cathodes.

Impact of Electrolyte on Direct-Contact Prelithiation of Silicon-Graphite Anodes in Lithium-Ion Cells with High-Nickel Cathodes

Silicon-based anodes offer high specific capacities to enhance the energy density of lithium-ion batteries, but are severely hindered by the immense volume expansion and subsequent breakage of the solid-electrolyte-interphase (SEI) during cycling. Herein, we utilize an effective strategy, known as direct-contact prelithiation, to mitigate the challenges associated with expansion and surface instability in SiOx/graphite (SG) anodes. It involves introducing lithium into the anode via physical contact with lithium metal and electrolyte before cycling. Prelithiation of SG anodes with an advanced localized high-concentration electrolyte is shown to develop a mechanically robust artificial SEI that tolerates better the electrode volume expansion. The modified SG anode paired with the high-Ni cathode LiNi0.90Mn0.05Co0.05O2 delivers a high initial capacity of 191 mA h g-1 with 80% capacity retention over 150 cycles, compared to 46% retention with a conventional electrolyte. The bolstered SEI layer with reduced surface reactivity is due to the reduced electrolyte consumption and regulated SEI formation during cycling. Furthermore, the advanced electrolyte and fortified SG anode help reduce cathode degradation, transition-metal dissolution, and loss of active lithium. This study highlights viable prelithiation strategies to stabilize Si-based anodes for high-energy-density batteries through electrolyte design.

In Situ Construction of a Multifunctional Interphase Enabling Continuous Capture of Unstable Lattice Oxygen Under Ultrahigh Voltages

The use of nickel-rich layered materials as cathodes can boost the energy density of lithium batteries. However, developing a safe and long-term stable nickel-rich layered cathode is challenging primarily due to the release of lattice oxygen from the cathode during cycling, especially at high voltages, which will cause a series of adverse effects, leading to battery failure and thermal runaway. Surface coating is often considered effective in capturing active oxygen species; however, its process is rather complicated, and it is difficult to maintain intact on the cathode with large volume changes during cycling. Here, we propose an in situ construction of a multifunctional cathode/electrolyte interphase (CEI), which is easy to prepare, repairable, and, most importantly, capable of continuously capturing active oxygen species during the entire life span. This unique protective mechanism notably improves the cycling stability of Li||LiNi0.8Co0.1Mn0.1O2 (NCM811) cells at rigorous working conditions, including ultrahigh voltage (4.8 V), high temperature (60 °C), and fast charging (10 C). An industrial 1 A h graphite||NCM811 pouch cell achieved stable operation of 600 cycles with a capacity retention of 79.6% at 4.4 V, exhibiting great potential for practical use. This work provides insightful guidance for constructing a multifunctional CEI to bypass limitations associated with high-voltage operations of nickel-rich layered cathodes.

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.

Effect of Oxidative Synthesis Conditions on the Performance of Single-Crystalline LiMn2- x Mx O4 (M = Al, Fe, and Ni) Spinel Cathodes in Lithium-Ion Batteries

LiMn2 O4 (LMO) spinel cathode materials attract much interest due to the low price of manganese and high power density for lithium-ion batteries. However, the LMO cathodes suffer from the Mn dissolution problem at particle surfaces, which accelerates capacity fade. Herein, the authors report that the oxidative synthesis condition is a key factor in the cell performance of single-crystalline LiMn2- x Mx O4 (0.03 ≤ x ≤ 0.1, M = Al, Fe, and Ni) cathode materials prepared at 1000 °C. The use of oxygen flow during the spinel-phase formation minimizes the presence of oxygen vacancies generated at 1000 °C, thereby yielding a stoichiometrically doped LMO product; otherwise, the spinel cathode prepared in atmospheric air readily loses capacity due to the oxygen vacancies in the structure. As a way of circumventing the use of oxygen flow, a one-pot, two-step heating in air at 1000 °C and subsequently at 600 °C is used to yield the stoichiometric LMO product. The lithiation heating at 1000-600 ⁰C resulted in a significant improvement in the cycling stability of the prepared LMO cathode in graphite-based full cells. This study on oxidative synthesis conditions also confirms the advantage of minimizing the surface area of the cathode particles.

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.

In situ neutron diffraction to investigate the solid-state synthesis of Ni-rich cathode materials

Studying chemical reactions in real time can provide unparalleled insight into the evolution of intermediate species and can provide guidance to optimize the reaction conditions. For solid-state synthesis reactions, powder diffraction has been demonstrated as an effective tool for resolving the structural evolution taking place upon heating. The synthesis of layered Ni-rich transition-metal oxides at a large scale (grams to kilograms) is highly relevant as these materials are commonly employed as cathodes for Li-ion batteries. In this work, in situ neutron diffraction was used to monitor the reaction mechanism during the high-temperature synthesis of Ni-rich cathode materials with a varying ratio of Ni:Mn from industrially relevant hydroxide precursors. Rietveld refinement was further used to model the observed phase evolution during synthesis and compare the behaviour of the materials as a function of temperature. The results presented herein confirm the suitability of in situ neutron diffraction to investigate the synthesis of batches of several grams of electrode materials with well-controlled stoichiometry. Furthermore, monitoring the structural evolution of the mixtures with varying Ni:Mn content in real time reveals a delayed onset of li-thia-tion as the Mn content is increased, necessitating the use of higher annealing temperatures to achieve layering.

Heuristics for Molten-Salt Synthesis of Single-Crystalline Ultrahigh-Nickel Layered Oxide Cathodes

In pursuit of Li-ion batteries with higher energy density, ultrahigh-nickel layered oxides are a leading candidate for next-generation cathode materials. Single-crystalline morphology offers a neat solution to the poor stability of ultrahigh-Ni cathodes; a lower active surface area mitigates electrolyte decomposition at high voltages, and the elimination of grain boundaries improves mechanical resilience and increases volumetric energy density. However, single-crystal cathodes possess their own challenges, several of which originate from synthesis at elevated temperatures meant to induce grain growth. Molten-salt synthesis is an alternative method for obtaining single crystals, accelerating grain growth through the presence of a molten flux without the need for increased temperature. Herein, we offer heuristic guidelines for molten-salt synthesis, discussing key factors for designing reaction mixtures and the necessary exploratory research for novel molten salt/cathode systems. The influence of different salts and synthesis conditions on the morphology and properties of single-crystal LiNiO₂ is presented. It is found that oxidative salts, such as Li₂O₂ and LiNO₃, are crucial to supplementing dissolution of gaseous oxygen into the molten phase. Through these discussions, this work aims to provide a set of overarching principles for obtaining higher-quality single-crystal layered oxide cathodes and engender more rigorous and impactful investigation into their fundamental nature and applications.

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.

Crossover Effects in Lithium-Metal Batteries with a Localized High Concentration Electrolyte and High-Nickel Cathodes

While crossover effects, such as transition-metal dissolution, are well-understood in lithium-ion batteries, there is a limited understanding of the effect of crossed-over chemical species in cells with oxide cathodes and lithium-metal anodes. In this work, the effects of cathode-to-anode and anode-to-cathode crossover are explored in cells with a high-nickel cathode, lithium-metal anode, and a localized high-concentration electrolyte (LHCE). Dramatic differences are found among cells; a lithium-metal anode paired with a high-nickel cathode has three times less solid-electrolyte interphase growth than a lithium-metal anode paired with lithium metal. Meanwhile, the cathode paired with lithium metal has 2-3 times higher capacity fade than the same cathode paired with graphite. Decomposition and crossover of the FSI salt is identified as the main source of these changes. The fluorine in the salt is first stripped off at the lithium-metal anode, and the remaining sulfur and nitrogen cross over to the cathode. Although the reduction in fluorine content harms the surface stability of the cathode, the lithium-metal anode benefits from the increased fluorine content. Because the lithium-metal anode is typically the bottleneck for cells with thin lithium, crossover is a major factor in the enhanced performance of lithium-metal batteries with LHCE.

Flux upcycling of spent NMC 111 to nickel-rich NMC cathodes in reciprocal ternary molten salts

The proper handling of end-of-life (EOL) lithium-ion batteries (LIBs) has become an urgent and challenging issue with the surging use of LIBs, in which recovering high-value cathodes not only relieves the pressure on the raw material supply chain but also minimizes environmental pollution. Beyond direct recycling of spent cathodes to their pristine states, the direct upcycling of spent cathodes to the next-generation cathodes is of great significance to maximize the value of spent materials and to sustain the fast development of LIBs. Herein, a “reciprocal ternary molten salts” (RTMS) system was developed to directly upcycle spent NMC 111 to Ni-rich NMCs by simultaneously realizing the addition of Ni and the relithiation of Li in spent NMC 111. After RTMS flux upcycling, the obtained Ni-rich NMCs exhibited an α-NaFeO₂-type layered structure, restored Li content, and excellent performance, which is very similar to that of the pristine NMC 622.

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A “reciprocal ternary molten salts” (RTMS) system is developed for upcycling

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Directly upcycling of spent NMC 111 to Ni-rich NMC (NMC 622) is realized in air

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RTMS provides the Li source and a flux oxygen-rich environment for upcycling

Oxygen Loss in Layered Oxide Cathodes for Li-Ion Batteries: Mechanisms, Effects, and Mitigation

Layered lithium transition metal oxides derived from LiMO₂ (M = Co, Ni, Mn, etc.) have been widely adopted as the cathodes of Li-ion batteries for portable electronics, electric vehicles, and energy storage. Oxygen loss in the layered oxides is one of the major factors leading to cycling-induced structural degradation and its associated fade in electrochemical performance. Herein, we review recent progress in understanding the phenomena of oxygen loss and the resulting structural degradation in layered oxide cathodes. We first present the major driving forces leading to the oxygen loss and then describe the associated structural degradation resulting from the oxygen loss. We follow this analysis with a discussion of the kinetic pathways that enable oxygen loss, and then we address the resulting electrochemical fade. Finally, we review the possible approaches toward mitigating oxygen loss and the associated electrochemical fade as well as detail novel analytical methods for probing the oxygen loss.

High Nickel and No Cobalt─The Pursuit of Next-Generation Layered Oxide Cathodes

The prosperity of the electric vehicle industry is driving the research and development of lithium-ion batteries. As one of the core components in the entire battery system, cathode materials are currently facing major challenges in pushing a higher capacity up to the materials' theoretical limits and transitioning away from unaffordable metals. The search for next-generation cathode materials has shifted to high-nickel and cobalt-free cathodes to meet these requirements. In this review, we distinctly point out the shortcomings of cobalt in stabilizing layered structures and systematically summarize the recent efforts to eliminate cobalt and achieve higher nickel content in layered cathode materials. Finally, a reasonable prospect is put forward for further development of layered cathode materials and other promising candidates, which is likely to spur a wave of efforts toward developing high-performance and low-cost Li-ion batteries.

Influence of Calendering on the Electrochemical Performance of LiNi0.9Mn0.05Al0.05O2 Cathodes in Lithium-Ion Cells

Electrode calendering is a necessary process used in industry to improve the volumetric capacity of lithium-ion batteries. However, calendering high-nickel cathodes leads to electrode particle pulverization, raising concerns of a reduced cycle life due to parasitic side reactions. We present here an investigation of the impact of calendering on the morphology and electrochemical performance of the cobalt-free layered oxide cathode LiNi_0.9Mn_0.05Al_0.05O₂ (NMA-90). We find that secondary particle pulverization and fusion simultaneously occur at sufficiently high pressures. The initial surface area of the cathode is shown to increase with the degree of calendering, despite the higher likelihood of secondary particle fusion. Long-term cycling of full coin cells assembled with the NMA-90 cathode and the graphite anode indicates that cells with higher degrees of cathode calendering exhibit lower capacity fade compared to uncalendered cathodes. Hybrid pulse-power tests demonstrate that the usable capacity range of cells with calendered cathodes far exceeds those with uncalendered cells after long-term cycling. The improved capacity retention and pulse-power performance are attributed to the enhanced mechanical properties of the electrode after calendering that prevents loss of the primary particle contact during long-term cycling. We find that calendering high-nickel NMA-90 to industrially relevant densities does not have a detrimental effect on capacity fade, marking an important step toward commercial adoption.