Battery research depends upon up-to-date information on the cell characteristics found in current electric vehicles, which is exacerbated by the deployment of novel formats and architectures. This necessitates open access to cell characterization data. Therefore, this study examines the architecture and performance of first-generation Tesla 4680 cells in detail, both by electrical characterization and thermal investigations at cell-level and by disassembling one cell down to the material level including a three-electrode analysis. The cell teardown reveals the complex cell architecture with electrode disks of hexagonal symmetry as well as an electrode winding consisting of a double-sided and homogeneously coated cathode and anode, two separators and no mandrel. A solvent-free anode fabrication and coating process can be derived. Energy-dispersive X-ray spectroscopy as well as differential voltage, incremental capacity and three-electrode analysis confirm a NMC811 cathode and a pure graphite anode without silicon. On cell-level, energy densities of 622.4 Wh/L and 232.5 Wh/kg were determined while characteristic state-of-charge dependencies regarding resistance and impedance behavior are revealed using hybrid pulse power characterization and electrochemical impedance spectroscopy. A comparatively high surface temperature of ∼70 °C is observed when charging at 2C without active cooling. All measurement data of this characterization study are provided as open source.
The Electrochemical Society (ECS) was founded in 1902 to advance the theory and practice at the forefront of electrochemical and solid state science and technology, and allied subjects.
ISSN: 1945-7111
JES is the flagship journal of The Electrochemical Society. Published continuously from 1902 to the present, JES remains one of the most highly-cited journals in electrochemistry and solid-state science and technology.
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Manuel Ank et al 2023 J. Electrochem. Soc. 170 120536
Yuliya Preger et al 2020 J. Electrochem. Soc. 167 120532
Energy storage systems with Li-ion batteries are increasingly deployed to maintain a robust and resilient grid and facilitate the integration of renewable energy resources. However, appropriate selection of cells for different applications is difficult due to limited public data comparing the most commonly used off-the-shelf Li-ion chemistries under the same operating conditions. This article details a multi-year cycling study of commercial LiFePO4 (LFP), LiNixCoyAl1−x−yO2 (NCA), and LiNixMnyCo1−x−yO2 (NMC) cells, varying the discharge rate, depth of discharge (DOD), and environment temperature. The capacity and discharge energy retention, as well as the round-trip efficiency, were compared. Even when operated within manufacturer specifications, the range of cycling conditions had a profound effect on cell degradation, with time to reach 80% capacity varying by thousands of hours and cycle counts among cells of each chemistry. The degradation of cells in this study was compared to that of similar cells in previous studies to identify universal trends and to provide a standard deviation for performance. All cycling files have been made publicly available at batteryarchive.org, a recently developed repository for visualization and comparison of battery data, to facilitate future experimental and modeling efforts.
George E. Blomgren 2017 J. Electrochem. Soc. 164 A5019
This year, the battery industry celebrates the 25th anniversary of the introduction of the lithium ion rechargeable battery by Sony Corporation. The discovery of the system dates back to earlier work by Asahi Kasei in Japan, which used a combination of lower temperature carbons for the negative electrode to prevent solvent degradation and lithium cobalt dioxide modified somewhat from Goodenough's earlier work. The development by Sony was carried out within a few years by bringing together technology in film coating from their magnetic tape division and electrochemical technology from their battery division. The past 25 years has shown rapid growth in the sales and in the benefits of lithium ion in comparison to all the earlier rechargeable battery systems. Recent work on new materials shows that there is a good likelihood that the lithium ion battery will continue to improve in cost, energy, safety and power capability and will be a formidable competitor for some years to come.
Peter Keil et al 2016 J. Electrochem. Soc. 163 A1872
In this study, the calendar aging of lithium-ion batteries is investigated at different temperatures for 16 states of charge (SoCs) from 0 to 100%. Three types of 18650 lithium-ion cells, containing different cathode materials, have been examined. Our study demonstrates that calendar aging does not increase steadily with the SoC. Instead, plateau regions, covering SoC intervals of more than 20%–30% of the cell capacity, are observed wherein the capacity fade is similar. Differential voltage analyses confirm that the capacity fade is mainly caused by a shift in the electrode balancing. Furthermore, our study reveals the high impact of the graphite electrode on calendar aging. Lower anode potentials, which aggravate electrolyte reduction and thus promote solid electrolyte interphase growth, have been identified as the main driver of capacity fade during storage. In the high SoC regime where the graphite anode is lithiated more than 50%, the low anode potential accelerates the loss of cyclable lithium, which in turn distorts the electrode balancing. Aging mechanisms induced by high cell potential, such as electrolyte oxidation or transition-metal dissolution, seem to play only a minor role. To maximize battery life, high storage SoCs corresponding to low anode potential should be avoided.
Jorn M. Reniers et al 2019 J. Electrochem. Soc. 166 A3189
The maximum energy that lithium-ion batteries can store decreases as they are used because of various irreversible degradation mechanisms. Many models of degradation have been proposed in the literature, sometimes with a small experimental data set for validation. However, a comprehensive comparison between different model predictions is lacking, making it difficult to select modelling approaches which can explain the degradation trends actually observed from data. Here, various degradation models from literature are implemented within a single particle model framework and their behavior is compared. It is shown that many different models can be fitted to a small experimental data set. The interactions between different models are simulated, showing how some of the models accelerate degradation in other models, altering the overall degradation trend. The effects of operating conditions on the various degradation models is simulated. This identifies which models are enhanced by which operating conditions and might therefore explain specific degradation trends observed in data. Finally, it is shown how a combination of different models is needed to capture different degradation trends observed in a large experimental data set. Vice versa, only a large data set enables to properly select the models which best explain the observed degradation.
Weilong Ai et al 2020 J. Electrochem. Soc. 167 013512
Whilst extensive research has been conducted on the effects of temperature in lithium-ion batteries, mechanical effects have not received as much attention despite their importance. In this work, the stress response in electrode particles is investigated through a pseudo-2D model with mechanically coupled diffusion physics. This model can predict the voltage, temperature and thickness change for a lithium cobalt oxide-graphite pouch cell agreeing well with experimental results. Simulations show that the stress level is overestimated by up to 50% using the standard pseudo-2D model (without stress enhanced diffusion), and stresses can accelerate the diffusion in solid phases and increase the discharge cell capacity by 5.4%. The evolution of stresses inside electrode particles and the stress inhomogeneity through the battery electrode have been illustrated. The stress level is determined by the gradients of lithium concentration, and large stresses are generated at the electrode-separator interface when high C-rates are applied, e.g. fast charging. The results can explain the experimental results of particle fragmentation close to the separator and provide novel insights to understand the local aging behaviors of battery cells and to inform improved battery control algorithms for longer lifetimes.
Mark E. Orazem and Burak Ulgut 2024 J. Electrochem. Soc. 171 040526
Recent battery papers commonly employ interpretation models for which diffusion impedances are in series with interfacial impedance. The models are fundamentally flawed because the diffusion impedance is inherently part of the interfacial impedance. A derivation for faradaic impedance is presented which shows how the charge-transfer resistance and diffusion resistance are functions of the concentration of reacting species at the electrode surface, and the resulting impedance model incorporates diffusion impedances as part of the interfacial impedance. Conditions are identified under which the two model formulations yield the same results. These conditions do not apply for batteries.
Chang-Hui Chen et al 2020 J. Electrochem. Soc. 167 080534
Presented here, is an extensive 35 parameter experimental data set of a cylindrical 21700 commercial cell (LGM50), for an electrochemical pseudo-two-dimensional (P2D) model. The experimental methodologies for tear-down and subsequent chemical, physical, electrochemical kinetics and thermodynamic analysis, and their accuracy and validity are discussed. Chemical analysis of the LGM50 cell shows that it is comprised of a NMC 811 positive electrode and bi-component Graphite-SiOx negative electrode. The thermodynamic open circuit voltages (OCV) and lithium stoichiometry in the electrode are obtained using galvanostatic intermittent titration technique (GITT) in half cell and three-electrode full cell configurations. The activation energy and exchange current coefficient through electrochemical impedance spectroscopy (EIS) measurements. Apparent diffusion coefficients are estimated using the Sand equation on the voltage transient during the current pulse; an expansion factor was applied to the bi-component negative electrode data to reflect the average change in effective surface area during lithiation. The 35 parameters are applied within a P2D model to show the fit to experimental validation LGM50 cell discharge and relaxation voltage profiles at room temperature. The accuracy and validity of the processes and the techniques in the determination of these parameters are discussed, including opportunities for further modelling and data analysis improvements.
Yuriy V. Tolmachev 2023 J. Electrochem. Soc. 170 030505
We present a quantitative bibliometric study of flow battery technology from the first zinc-bromine cells in the 1870's to megawatt vanadium RFB installations in the 2020's. We emphasize, that the cost advantage of RFBs in multi-hour charge-discharge cycles is compromised by an inferior energy efficiency of these systems, and that there are limits on the efficiency improvement due to internal cross-over and the cost of power (at low current densities) and due to an acceptable pressure drop (at high current densities). Differences between lithium-ion and vanadium redox flow batteries (VRFBs) are discussed from the end-user perspective. We conclude, that the area-specific resistance, cross-over current and durability of contemporaneous VRFBs are appropriate for commercialization in multi-hour stationary energy storage markets, and the most import direction in the VRFB development today is the reduction of stack materials and manufacturing costs. Chromium-iron RFBs should be given a renewed attention, since it seems to be the most promising durable low-energy-cost chemistry.
Peter M. Attia et al 2022 J. Electrochem. Soc. 169 060517
Lithium-ion batteries can last many years but sometimes exhibit rapid, nonlinear degradation that severely limits battery lifetime. In this work, we review prior work on "knees" in lithium-ion battery aging trajectories. We first review definitions for knees and three classes of "internal state trajectories" (termed snowball, hidden, and threshold trajectories) that can cause a knee. We then discuss six knee "pathways", including lithium plating, electrode saturation, resistance growth, electrolyte and additive depletion, percolation-limited connectivity, and mechanical deformation—some of which have internal state trajectories with signals that are electrochemically undetectable. We also identify key design and usage sensitivities for knees. Finally, we discuss challenges and opportunities for knee modeling and prediction. Our findings illustrate the complexity and subtlety of lithium-ion battery degradation and can aid both academic and industrial efforts to improve battery lifetime.
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Louis V. Morris et al 2024 J. Electrochem. Soc. 171 050501
We have explored a set of structurally related fluorinated and non-fluorinated organosilicon additives and quantified their rates of reaction with the superoxide radical anion O2•−. using rapid-scan cyclic voltammetry. Absolute reaction rate measurements in acetonitrile solvent show that O2•− reacts with the fluorinated OS compounds with bimolecular rate constants kBM more than 1000x larger than kBM for the reaction between O2•− and ethylene carbonate. We further identified the products of reaction of a model OS compound using multiple nuclear magnetic resonance (NMR) methods and with gas chromatography/mass spectroscopy. Chemical analysis measurements show that addition of potassium superoxide KO2 to a model fluorinated OS compound produces only one product. Our results indicate that that OS compounds improve battery performance by rapidly scavenging O2•− in a way that produces a stable product and reduces or eliminates the competing chemical pathways associated with carbonate breakdown. These results provide new insights into how chemical structure impacts critical chemical reactions and may guide the design of new additives that further improve battery safety and stability.
Ramin Masoudi et al 2024 J. Electrochem. Soc. 171 053501
The role of batteries in electrification of vehicles is eminent; thus, a dynamic model that represents the physics-based phenomena of the battery system at a minimum computational cost is essential in the model-based design of electrified vehicle control systems. Furthermore, robustness of the reduced-order battery model when maintaining the dominant physics-based phenomena governing the dynamic behavior of the battery system is crucial. Characterization of the power signal applied to the lithium-ion battery in the energy management controller of a plug-in hybrid electric vehicle shows that there is a dominant frequency range in the input signal to the battery. This key feature can be considered as a basis to construct a reduced-order model in which the training input is different from the original power signal. The original idea in this paper is to generate the training input by applying a low-pass filter to the white-noise random signal to maintain the same dominant frequency range observed in the original power signal. Response of the reduced-order model, constructed using the proper orthogonal decomposition, compared to the high-fidelity battery model shows promising results; a maximum relative error of 1% was obtained for the battery state of charge while simulation time was reduced by 42.9%.
Xuan Dinh Ngo et al 2024 J. Electrochem. Soc. 171 056503
Insight into the phase-dependent electron transfer kinetics and electrocatalytic activity of metal oxide nanostructures is important in the rational design of functional nanostructures for realizing high-performance electrochemical sensors. This study focuses on elucidating the effect of the crystalline phase on the electron transfer kinetics and electrocatalytic activity of iron(III) oxide. The α-FeOOH, γ-Fe2O3, and α-Fe2O3 nanorods were designed by using a simple chemical method and calcining process. The phase-dependent difference in the electron transfer kinetics and electrocatalytic activity toward the sensitive response of chloramphenicol (CAP) is observed by the transformation from α-FeOOH to γ-Fe2O3, and from α-FeOOH to α-Fe2O3 nanorods. We found that the oxygen vacancies formed in phase transformation from α-FeOOH to α-Fe2O3 is a key factor in promoting the electrochemical reduction of chloramphenicol. The α-Fe2O3 nanorods-based electrochemical sensors showed a linear response in the CAP concentration range from 0.1 to 75 μM with a limit of detection of 60 nM and an electrochemical sensitivity of 2.86 μA μM−1 cm−2. This work further provides valuable physical insight into the phase-dependent electron transfer kinetics and electrocatalytic activity of metal oxide nanostructures for the rational design of sensing interface.
Kabita Lakra et al 2024 J. Electrochem. Soc. 171 052501
Cuprous oxide (Cu2O) thin films, antithetically exhibiting n-type conductivity, were electro–deposited on Fluorine-doped Tin Oxide (FTO) coated glass substrates. Linear sweep voltammetry, chronoamperometry, and chronopotentiometry studies coupled with structural characterization of the deposit identify the occurrence of multiple reduction reactions, including "corrosion" of Cu2O to Cu. Interestingly, an underpotential conversion (negative of +0.039 V vs Ag/AgCl) of the Cu2O film to Cu islands is observed during potentiostatic deposition. The same process is also shown as a potential spike in chronopotentiometry curves, during galvanostatic deposition, at current densities that are cathodic of −0.2 mAcm−1. The reason for the formation of Cu is attributed to the decrease in local pH in the vicinity of the working electrode, whence thermodynamic conditions favor the formation of Cu. The proroguation of Cu formation is achieved by continuously stirring the solution, thereby stabilizing the pH at the electrode. Deferment of film corrosion to increasingly longer times is observed with increasing stirring rates. Mott-Schottky analysis of phase-pure films reveals the formation of degenerately doped n-type Cu2O films (n ∼1020 cm−3). The phase pure Cu2O films could be used as an electron transport layer in several photo-conversion devices and ultimately pave the way for an oxide homojunction device.
Lilian Danielle de Moura Torquato et al 2024 J. Electrochem. Soc. 171 055502
The development of bioelectrochemical systems requires careful selection of both their biotic and abiotic components to obtain sustainable devices. Herein, we report a biophotoelectrode obtained with polyhydroxybutyrate (PHB), a biopolymer, which purple non-sulphur bacteria produce as an energy stock under specific environmental conditions. The electrode was obtained by casting a mixture composed of PHB and carbon fibers in a 3:2 mass ratio. Following, the composite material was modified with polydopamine and thermally treated to obtain a hydrophilic electrode with improved electrochemical behavior. The bio-based electrode was tested with metabolically active cells of Rhodobacter capsulatus embedded in a biohybrid matrix of polydopamine. The system achieved enhanced catalytic activity under illumination, with an 18-fold increase in photocurrent production compared to biophotoelectrodes based on glassy carbon, reaching a current density of 12 ± 3 μA cm−2, after 30 min of light exposure at +0.32 V. The presented biocompatible electrode provides a sustainable alternative to metal-based and critical raw material-based electrodes for bioelectrochemical systems.
Highlights
Biobased electrode for microbial electrochemical systems.
Bacteria-produced polymer for devices with enhanced colonization.
Improved biofilm formation and photocurrent generation.
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Jiashuai Wang et al 2024 J. Electrochem. Soc. 171 040527
The growing demand for energy storage application has facilitated the development of Li-ion rechargeable batteries (LIBs). As such, there is an urgent need to design electrodes with a high specific energy and long cycle life. The evolution of conventional LIBs cathode materials in past 30 years has arrived at a bottleneck. Fortunately, the finding of the lithium-rich cation disordered rocksalt (DRXs) has largely broadened the element ranges of the promising cathode in the past several years. Compared with the classical cation-ordered oxides, the DRXs display a large charge storage capacity based on both transition metal and oxygen redox capacity. In addition, their wide compositional space and cobalt-free characteristic would greatly reduce production costs in promoting the commercialization process. Herein, we make an overview of the recent progress for DRXs materials, in terms of their compositions and structure, Li diffusion, charge storage mechanisms, and different redox centra-based system. The key challenges to practical application are also discussed. Last but not least, in order to design high-performance DRXs, we outlined perspectives in developing DRXs for the next generation of LIB cathodes.
Pooja Saxena and Prashant Shukla 2024 J. Electrochem. Soc. 171 047504
Wearable sensors offer a non-invasive, continuous, and personalized approach to monitor various physiological and environmental parameters. Among the various materials used in the fabrication of wearable sensors, polymers have gained significant attention due to their versatile properties, low cost, and ease of integration. We present a comprehensive review of recent advances and challenges in the development of polymer-based wearable sensors. We begin by highlighting the key characteristics of wearable sensors, emphasizing their potential applications and advantages. Subsequently, we delve into the various types of polymers employed for sensor fabrication, such as conductive polymers, elastomers, and hydrogels. The unique properties of each polymer and its suitability for specific sensing applications are discussed in detail. We also address the challenges faced in the development of polymer-based wearable sensors and describes the mechanism of action in these kinds of wearable sensor-capable smart polymer systems. Contact lens-based, textile-based, patch-based, and tattoo-like designs are taken into consideration. Additionally, we paper discuss the performance of polymer-based sensors in real-world scenarios, highlighting their accuracy, sensitivity, and reliability when applied to healthcare monitoring, motion tracking, and environmental sensing. In conclusion, we provide valuable insights into the current state of polymer-based wearable sensors, their fabrication techniques, challenges, and potential applications.
Bianca-Maria Tuchiu et al 2024 J. Electrochem. Soc. 171 047502
Topical treatments rely on drugs that play a crucial role in addressing skin and mucous membrane disorders. Therefore, it is highly needed to utilize accurate analytical techniques that can determine the concentration of these chemicals in various sample matrices, including pharmaceuticals, food, and water. Currently, electrochemical sensors are predominantly used in specific fields such as biomedical, industrial, and environmental monitoring, while they have not yet been incorporated into the pharmaceutical manufacturing industry. However, electrochemical methods employing an expanding range of sensors provide a reliable, cost-effective, and efficient substitute for classical analytical methods. Their potential is highly favorable, offering possibilities for simultaneous determination, miniaturization, and real-time on-site monitoring. This work covers numerous sensors designed between 2020 and 2023 for the determination of topical drugs, highlighting their respective benefits and drawbacks while illuminating emerging trends. Moreover, it discusses the correlation between the used materials and the ease of manufacturing, to the achieved results, including dynamic range, detection limit, sensitivity, and selectivity. This work aims to serve as a valuable resource for researchers, engineers, and policymakers in the evolving field of electrochemical sensing by providing guidance and facilitating decision-making, which could lead to significant innovations in sensor technology.
Richard Bertram Church and A. John Hart 2024 J. Electrochem. Soc. 171 040512
Three-dimensional (3D) battery architectures have been envisioned to enable high energy density electrodes without the associated power drop experienced by planar cells. However, the development of 3D cells is hampered by difficulties producing conformal solid-state electrolytes (SSE), solid polymer electrolytes (SPE) and gel polymer electrolytes (GPE) that are pinhole-free and have adequate ionic conductivities. Fortunately, electrolytes in 3D cells are often utilized at lower thickness, which may compensate the decreased ionic conductivity. Here, we comprehensively review potential 3D SSE, SPE and GPE electrolyte materials by compiling their thickness and room temperature ionic conductivity. We use area specific resistance (ASR) as a metric to compare 3D electrolytes with one another and conventional electrolytes. We find that certain process-material combinations, such as atomic layer deposition of SSEs, electrodeposition of SPEs and GPEs, and initiated chemical vapor deposition of SPEs demonstrate ASRs beneath the interfacial impedances of Li-based systems and approach state-of-the-art electrolytes. We also comment on additional factors, such as electrochemical stability, that should be evaluated when determining 3D electrolyte suitability. Future research should focus on adapting known materials chemistries for conformal deposition techniques to further improve the ionic conductivity, as these techniques are capable of producing the necessary thicknesses and conformality.
Raphaël Gass et al 2024 J. Electrochem. Soc. 171 034511
Technologies based on the use of hydrogen are promising for future energy requirements in a more sustainable world. Consequently, modelling fuel cells is crucial, for instance, to optimize their control to achieve excellent performance, to test new materials and configurations on a limited budget, or to consider their degradation for improved lifespan. To develop such models, a comprehensive study is required, encompassing both well-established and the latest governing laws on matter transport and voltage polarization for Proton Exchange Membrane Fuel Cells (PEMFCs). Recent articles often rely on outdated or inappropriate equations, lacking clear explanations regarding their background. Indeed, inconsistent understanding of theoretical and experimental choices or model requirements hinders comprehension and contributes to the misuse of these equations. Additionally, specific researches are needed to construct more accurate models. This study aims to offer a comprehensive understanding of the current state-of-the-art in PEMFC modeling. It clarifies the corresponding governing equations, their usage conditions, and assumptions, thus serving as a foundation for future developments. The presented laws and equations are applicable in most multi-dimensional, dynamic, and two-phase PEMFC models.
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Hong Zhang et al 2024 J. Electrochem. Soc. 171 047510
Ordered Pt/SnO2 composite porous thin films were prepared for fabrication of planar mixed-potential hydrogen sensors. Characterization of the Pt/SnO2 films revealed that Pt elements were primarily loaded in Pt° form on the SnO2 film surface and did not significantly change the morphology of the film electrodes. The potentiometric response of Pt/SnO2 thin films to hydrogen varied with the Pt loading contents. Compared to the pristine SnO2 film, the 1 at% and 2 at% Pt-loaded SnO2 composite films exhibited 1.6 and 2.0 times higher potentiometric response to 300 ppm hydrogen at 500 °C, with a similar response time of 6–10.5 s. By assembling an array of sensors composed of SnO2 films loaded with 1 at% and 2 at% Pt, and using principal component analysis, discrimination of hydrogen and four interfering gases (ammonia, carbon monoxide, nitrogen dioxide, and propane) in the concentration range of 100–300 ppm was achieved. The sensing behaviors of the Pt/SnO2 composite thin films were discussed in relation to the competitive promotion effects for the heterogeneous and electrochemical catalytic activities by Pt loading.
Highlights
Potentiometric hydrogen sensors based on Pt/SnO2 thin films were fabricated.
Hydrogen sensing response was enhanced by loading 1 at% and 2 at% Pt.
The sensing behavior was discussed by the Pt competitive promotion effects.
Discrimination of hydrogen and four interfering gases was achieved.
S. Yanev et al 2024 J. Electrochem. Soc. 171 020512
Li-In electrodes are widely applied as counter electrodes in fundamental research on Li-metal all-solid-state batteries. It is commonly assumed that the Li-In anode is not rate limiting, i.e. the measurement results are expected to be representative of the investigated electrode of interest. However, this assumption is rarely verified, and some counterexamples were recently demonstrated in literature. Herein, we fabricate Li-In anodes in three different ways and systematically evaluate the electrochemical properties in two- and three-electrode half-cells. The most common method of pressing Li and In metal sheets together during cell assembly resulted in poor homogeneity and low rate performance, which may result in data misinterpretation when applied for investigations on cathodic phenomena. The formation of a Li-poor region on the separator side of the anode is identified as a major kinetic bottleneck. An alternative fabrication of a Li-In powder anode resulted in no kinetic benefits. In contrast, preparing a composite from Li-In powder and sulfide electrolyte powder alleviated the kinetic limitation, resulted in superior rate performance, and minimized the impedance. The results emphasize the need to fabricate optimized Li-In anodes to ensure suitability as a counter electrode in solid-state cells.
Highlights
The fabrication of Li-In anodes needs to be optimized to ensure suitability as a counter electrode in sulfide all-solid-state batteries.
The Li-In counter electrode may often be the limiting factor of sulfide all-solid-state halfcells.
Pressing Li and In foil together results in a kinetically limited anode.
Composites from Li-In and sulfide electrolyte result in stable reference potential, superior rate performance and low impedance of the counter electrode.
Ramver Singh et al 2024 J. Electrochem. Soc. 171 013501
Electrical discharge micromachining (EDM) poses challenges to the fatigue-life performance of machined surfaces due to thermal damage, including recast layers, heat-affected zones, residual stress, micro-cracks, and pores. Existing literature proposes various ex situ post-processing techniques to mitigate these effects, albeit requiring separate facilities, leading to increased time and costs. This research involves an in situ sequential electrochemical post-processing (ECPP) technique to enhance the quality of EDMed micro-holes on titanium. The study develops an understanding of the evolution of overcutting during ECPP, conducting unique experiments that involve adjusting the initial radial interelectrode gap (utilizing in situ wire-electrical discharge grinding) and applied voltage. Additionally, an experimentally validated transient finite element method (FEM) model is developed, incorporating the passive film formation phenomenon for improved accuracy. Compared to EDM alone, the sequential EDM-ECPP approach produced micro-holes with superior surface integrity and form accuracy, completely eliminating thermal damage. Notably, surface roughness (Sa) was reduced by 80% after the ECPP. Increasing the voltage from 8 to 16 V or decreasing the gap from 60 to 20 μm rendered a larger overcut. This research's novelty lies in using a two-phase dielectric (water-air), effectively addressing dielectric and electrolyte cross-contamination issues, rendering it suitable for commercial applications.
Highlights
Better micro-hole quality through in situ sequential eco-friendly near-dry EDM & ECM
Successfully resolved dielectric-electrolyte cross-contamination in sequential processes
Unique experiments that adjust the initial radial IEG using in situ wire-EDG
Developed and validated a transient FEM model, incorporating passivation aspect
Achieved recast layer-free holes with Sa values approximately 80% lower than EDM holes
Yuefan Ji and Daniel T. Schwartz 2023 J. Electrochem. Soc. 170 123511
Analytical theory for second harmonic nonlinear electrochemical impedance spectroscopy (2nd-NLEIS) of planar and porous electrodes is developed for interfaces governed by Butler-Volmer kinetics, a Helmholtz (mainly) or Gouy-Chapman (introduced) double layer, and transport by ion migration and diffusion. A continuum of analytical EIS and 2nd-NLEIS models is presented, from nonlinear Randles circuits with or without diffusion impedances to nonlinear macrohomogeneous porous electrode theory that is shown to be analogous to a nonlinear transmission-line model. EIS and 2nd-NLEIS for planar electrodes share classic charge transfer RC and diffusion time-scales, whereas porous electrode EIS and 2nd-NLEIS share three characteristic time constants. In both cases, the magnitude of 2nd-NLEIS is proportional to nonlinear charge transfer asymmetry and thermodynamic curvature parameters. The phase behavior of 2nd-NLEIS is more complex and model-sensitive than in EIS, with half-cell NLEIS spectra potentially traversing all four quadrants of a Nyquist plot. We explore the power of simultaneously analyzing the linear EIS and 2nd-NLEIS spectra for two-electrode configurations, where the full-cell linear EIS signal arises from the sum of the half-cell spectra, while the 2nd-NLEIS signal arises from their difference.
Leonardo I. Astudillo and Hubert A. Gasteiger 2023 J. Electrochem. Soc. 170 124512
A major degradation mechanism of polymer electrolyte membrane fuel cells (PEMFCs) in transportation applications is the loss of the electrochemically active surface area (ECSA) of platinum cathode catalysts upon dynamic load cycling (resulting in cathode potential cycles). This is commonly investigated by accelerated stress tests (ASTs), cycling the cell voltage under H2/N2 (anode/cathode). Here we examine the degradation of membrane electrode assemblies with Vulcan carbon supported Pt catalysts over extended square-wave voltage cycles between 0.6-1.0 VRHE at 80 °C and 30%-100% RH under either H2/N2 or H2/Air; for the latter case, differential reactant flows were used, and the lower potential limit is controlled to correspond to the high-frequency resistance corrected cell voltage, assuring comparable aging conditions. Over the course of the ASTs, changes of the ECSA, the hydrogen crossover current, the proton conduction resistance and the oxygen transport resistance of the cathode electrode, as well as the differential-flow H2/O2 and H2/Air performance at 80 °C/100% RH were monitored. While the ECSA loss decreases with decreasing RH, it is independent of the gas feeds. Furthermore, the H2/Air performance loss only depends on the ECSA loss. ASTs under H2/N2 versus H2/Air only differ with regards to the chemical/mechanical degradation of the membrane.
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Yan et al
Developing efficient, low-price non-noble metal-based electrocatalysts for overall water splitting in alkaline medium remains a formidable challenge. In our work, Cr-doped CoP/Fe2P (Cr-CoP/Fe2P) flower-like microsphere was synthesized through a simple hydrothermal and phosphating process. The resulting Cr-CoP/Fe2P electrocatalyst shows significantly enhanced oxygen evolution reaction performance (262 mV @ 10 mA cm-2) and has a satisfactory hydrogen evolution reaction performance (114 mV @ 10 mA cm-2), coupled with favorable stability in an alkaline medium. Furthermore, when assembling Cr-CoP/Fe2P into an electrolytic cell, the two-electrode system can provide a current density of 10 mA cm-2 at a voltage of 1.61 V. At high current density, the performance of the electrolytic cell composed of Cr-CoP/Fe2P is superior to that of noble metal catalyst electrode pair. Electronic structure analysis and various characterizations confirm that Cr doping and the formation of CoP/Fe2P heterogeneous interfaces redistribute the electron densities of the active sites, enlarge the specific surface area, and enhance the aerophobicity of the catalysts, thereby improving the electrocatalytic property. This work provides a referable method for engineering highly efficient and stable non-noble polymetallic phosphides, which serve as bifunctional electrocatalyst for overall water splitting.
Tao et al
Nickel (Ni) film on patterned Ni- yttria-stabilized zirconia (YSZ) anode shows dynamic spreading and splitting during solid oxide fuel cell (SOFC) operation, where wettability of Ni on YSZ is greatly enhanced (Z. Jiao, N. Shikazono, J. Power Sources 396 119–123, 2018). In the present study, a physics-informed neural network (PINN) constrained by Cahn-Hilliard equation of phase field model is proposed to estimate the unknown parameters for predicting dynamic Ni movements of the patterned Ni-YSZ anode. The unknown parameters such as interface thickness and mobility are inversely inferred by PINN using top-view images obtained from the operando experiments. Obtained excess surface diffusivity values were three to four orders of magnitude larger than the values reported for surface diffusion in the literature. It is therefore considered that Ni spreading and splitting of patterned anode cannot be simply explained by surface diffusion, and other mechanisms should be introduced.
Han et al
Electrolyte supported Solid Oxide Cells (ESCs) with advanced thin-film Gd-doped ceria diffusion barrier layers between electrolyte and electrodes were assembled and electrochemically investigated in a so-called “rainbow” stack with 30 repeat units (RUs). The barrier layers were deposited onto the electrolyte supports via electron-beam physical evaporation deposition (EB-PVD) method at 600 oC. At the initial stage of the SOEC operation, the stack reached a high performance with an electrical efficiency of 99.65% at 75% steam conversion and a total power input of 1.98 kW. A long-term stack test was performed in SOEC mode for over 5000 h and demonstrated a low voltage degradation of approx. +11.3 mV·kh–1 per RU (+0.9% kh–1). The RUs with EB-PVD GDC thin-films revealed similar initial performance and degradation rate to the state-of-the-art cells with screen printed GDC layers. In this paper, the investigation mainly focuses on the electrochemical characteristics of RUs containing the EB-PVD thin-film GDC layers.
Likit-anurak et al
We report the development of an experimentally-validated computational fluid dynamics (CFD) model for simulation of an anhydrous HCl electrolyzer. The experimental data from 3 membrane variants was used to provide kinetic and membrane parameters for the model. The model not only accurately simulates overall electrolyzer performance, but it also provides key insights into the transport phenomena within the electrolyzer. The model allows simulation of experimental parameters like high HCl flowrates and increased cell pressure that pose a high safety risk to researchers. The model shows hotspots in the temperature distribution that will need to be addressed by flow field modification when scaling up the electrolysis process. The increasing of cell pressure reduces the gradient of current distribution throughout the electrolyzer and lowers the cell voltage required for a given current density. Increasing electrolyzer temperature reduces cell voltage by decreasing losses due to kinetic overpotential and ohmic overpotential. The implications of the simulated results are discussed, including potential limitations in our experiments and how the model can be used effectively when considering important steps like industry scale-up.
Marino et al
In the perspective of the transition of gas grids towards hydrogen/natural gas blends or even pure hydrogen, Solid Oxide Fuel Cells “SOFC” could play a crucial role as efficient and clean stationary Combined Heat and Power systems, flexibly operating on different feedstocks. A solid oxide fuel cell short stack is analyzed experimentally under different fuel gas compositions which emulate different gas grid transition scenarios. The testing campaign is defined with the aid of a preliminary system-level simulation which assesses system architecture and operating strategy (off-gas recirculation, external reforming, etc.). Experimental tests (polarization curves and performance/efficiency maps) are run in different operating conditions in terms of fuel utilization and temperature in three gas composition scenarios. 
To assess the efficiency of the SOFC unit under the different feedstock operation, different formulations of stack and system efficiencies are proposed and analyzed, based on the boundary conditions considered for the input/output energy streams. 
Experimental results were key to evaluate the different efficiency definitions proposed; albeit the highest voltage/power is obtained with the 100% H2 scenario, the efficiency may be higher with 100% NG and blend scenarios, due to the lower energy content of the input fuel.
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Louis V. Morris et al 2024 J. Electrochem. Soc. 171 050501
We have explored a set of structurally related fluorinated and non-fluorinated organosilicon additives and quantified their rates of reaction with the superoxide radical anion O2•−. using rapid-scan cyclic voltammetry. Absolute reaction rate measurements in acetonitrile solvent show that O2•− reacts with the fluorinated OS compounds with bimolecular rate constants kBM more than 1000x larger than kBM for the reaction between O2•− and ethylene carbonate. We further identified the products of reaction of a model OS compound using multiple nuclear magnetic resonance (NMR) methods and with gas chromatography/mass spectroscopy. Chemical analysis measurements show that addition of potassium superoxide KO2 to a model fluorinated OS compound produces only one product. Our results indicate that that OS compounds improve battery performance by rapidly scavenging O2•− in a way that produces a stable product and reduces or eliminates the competing chemical pathways associated with carbonate breakdown. These results provide new insights into how chemical structure impacts critical chemical reactions and may guide the design of new additives that further improve battery safety and stability.
Lilian Danielle de Moura Torquato et al 2024 J. Electrochem. Soc. 171 055502
The development of bioelectrochemical systems requires careful selection of both their biotic and abiotic components to obtain sustainable devices. Herein, we report a biophotoelectrode obtained with polyhydroxybutyrate (PHB), a biopolymer, which purple non-sulphur bacteria produce as an energy stock under specific environmental conditions. The electrode was obtained by casting a mixture composed of PHB and carbon fibers in a 3:2 mass ratio. Following, the composite material was modified with polydopamine and thermally treated to obtain a hydrophilic electrode with improved electrochemical behavior. The bio-based electrode was tested with metabolically active cells of Rhodobacter capsulatus embedded in a biohybrid matrix of polydopamine. The system achieved enhanced catalytic activity under illumination, with an 18-fold increase in photocurrent production compared to biophotoelectrodes based on glassy carbon, reaching a current density of 12 ± 3 μA cm−2, after 30 min of light exposure at +0.32 V. The presented biocompatible electrode provides a sustainable alternative to metal-based and critical raw material-based electrodes for bioelectrochemical systems.
Highlights
Biobased electrode for microbial electrochemical systems.
Bacteria-produced polymer for devices with enhanced colonization.
Improved biofilm formation and photocurrent generation.
Feng Han et al 2024 J. Electrochem. Soc.
Electrolyte supported Solid Oxide Cells (ESCs) with advanced thin-film Gd-doped ceria diffusion barrier layers between electrolyte and electrodes were assembled and electrochemically investigated in a so-called “rainbow” stack with 30 repeat units (RUs). The barrier layers were deposited onto the electrolyte supports via electron-beam physical evaporation deposition (EB-PVD) method at 600 oC. At the initial stage of the SOEC operation, the stack reached a high performance with an electrical efficiency of 99.65% at 75% steam conversion and a total power input of 1.98 kW. A long-term stack test was performed in SOEC mode for over 5000 h and demonstrated a low voltage degradation of approx. +11.3 mV·kh–1 per RU (+0.9% kh–1). The RUs with EB-PVD GDC thin-films revealed similar initial performance and degradation rate to the state-of-the-art cells with screen printed GDC layers. In this paper, the investigation mainly focuses on the electrochemical characteristics of RUs containing the EB-PVD thin-film GDC layers.
Kris Likit-anurak et al 2024 J. Electrochem. Soc.
We report the development of an experimentally-validated computational fluid dynamics (CFD) model for simulation of an anhydrous HCl electrolyzer. The experimental data from 3 membrane variants was used to provide kinetic and membrane parameters for the model. The model not only accurately simulates overall electrolyzer performance, but it also provides key insights into the transport phenomena within the electrolyzer. The model allows simulation of experimental parameters like high HCl flowrates and increased cell pressure that pose a high safety risk to researchers. The model shows hotspots in the temperature distribution that will need to be addressed by flow field modification when scaling up the electrolysis process. The increasing of cell pressure reduces the gradient of current distribution throughout the electrolyzer and lowers the cell voltage required for a given current density. Increasing electrolyzer temperature reduces cell voltage by decreasing losses due to kinetic overpotential and ohmic overpotential. The implications of the simulated results are discussed, including potential limitations in our experiments and how the model can be used effectively when considering important steps like industry scale-up.
Francesco Marino et al 2024 J. Electrochem. Soc.
In the perspective of the transition of gas grids towards hydrogen/natural gas blends or even pure hydrogen, Solid Oxide Fuel Cells “SOFC” could play a crucial role as efficient and clean stationary Combined Heat and Power systems, flexibly operating on different feedstocks. A solid oxide fuel cell short stack is analyzed experimentally under different fuel gas compositions which emulate different gas grid transition scenarios. The testing campaign is defined with the aid of a preliminary system-level simulation which assesses system architecture and operating strategy (off-gas recirculation, external reforming, etc.). Experimental tests (polarization curves and performance/efficiency maps) are run in different operating conditions in terms of fuel utilization and temperature in three gas composition scenarios. 
To assess the efficiency of the SOFC unit under the different feedstock operation, different formulations of stack and system efficiencies are proposed and analyzed, based on the boundary conditions considered for the input/output energy streams. 
Experimental results were key to evaluate the different efficiency definitions proposed; albeit the highest voltage/power is obtained with the 100% H2 scenario, the efficiency may be higher with 100% NG and blend scenarios, due to the lower energy content of the input fuel.
M. Sepe et al 2024 J. Electrochem. Soc. 171 054501
Optimization of proton exchange membrane water electrolyzers (PEMWE) has become a focus of researchers looking for a reliable way to generate power. A vital component to PEMWE operation is the porous transport layer (PTL) on the anode side, which is where oxygen is produced. The PTL must allow water access to the catalyst layer and remove oxygen simultaneously. In this work, a previously developed imaging technique is used to generate bilayer PTL structures. A multiscale modeling approach was used to study the effect of a bilayer PTL on oxygen evolution and PEMWE performance. First, a micro scale model was used to predict oxygen transport pathways through different PTL structures. Results showed that the bilayer PTL results in higher oxygen saturation and faster oxygen transport through the PTL. Second, a macro scale model was used to predict performance using bilayer PTLs. Predictions showed potential values between 10 and 20 mV below single layer potential values. This points to the bilayer improving PEMWE operation. Findings from this work show how the addition of a mesoporous layer to a PTL substrate will improve oxygen transport and removal from the catalyst surface, which will improve PEMWE performance.
Arvydas Survila et al 2024 J. Electrochem. Soc.
Anodic LS voltammograms of the alkaline Cu | Cu(II), glycine system were converted into mass-transport corrected Tafel plots considering that the glycinate anion L- takes part in the first stage of copper ionization. The anodic current density was normalized relative to the surface concentration of L- species, which was determined using the mass transfer model of chemically interacting species. The lability of the system was assessed based on available kinetic characteristics and specific experimental data. To linearize the Tafel plots, corrections were made to account for the insufficient mobility of the proton attached to glycine amino group. Obtained Tafel constants indicate that the second step of copper ionization, involving the oxidation of the intermediate copper(I)-glycine complex, is the rate-determining step.
Nicholas S Wilson et al 2024 J. Electrochem. Soc.
Matched glassy carbon electrodes in aqueous K2SO4 electrolytes were used to examine the effects of opposing electrode spacing on capacitive performance. Planar non-porous glassy carbon electrodes were used to avoid complications with porosity and roughness. Electrode spacing effects were examined in terms of device and individual electrode performance, using cyclic voltammetry, coupled with its deconvolution into residual, diffusional, and capacitive processes. Decreasing the spacing between electrodes led to a decrease in capacitive contributions, and a relative increase in diffusional and residual contributions, implying that individual electrodes were influencing the behaviour of each other. This is also consistent with the use of more dilute electrolytes. Electrode behaviour was modelled using the Poisson-Boltzmann equation, together with its integrated outputs of electric field and potential difference. For electrodes with the same amount of charge and a similar diffuse layer thickness, the electric field and potential drop was diminished because of their charge interaction. Conversely, it is shown that for a similar potential drop across the electrodes, the variable controlled in a cyclic voltammetry experiment, more charge accumulation is needed at the electrode-electrolyte interface to compensate for the counter charge generate from the opposing electrode.
Julian Stiegeler et al 2024 J. Electrochem. Soc.
Polymer electrolyte fuel cells for heavy-duty applications require lifetimes beyond 30,000 hours, which poses a durability challenge. In this study, we investigated the influence of various factors on loss of electrochemically active surface area (ECSA) in the cathode, which is a major limiting factor. We derive a parameter range from simulated drive cycles showing that the voltage ranges between 0.70 and 0.85 V and that the cells are in idle state at upper potential limit (UPL) most of the time. We evaluate the influence and interaction of UPL, lower potential limit (LPL), temperature, relative humidity, and cycle time on ECSA and performance at four different operating conditions after 10,000 potential cycles based on 25 experiments. The results indicate that UPL and the hold time at UPL have the strongest impact on degradation, while LPL has a small impact, which does not increase below the potential of full platinum reduction (0.55 V) or hold times longer than 2 seconds. Furthermore, the interaction of humidity with other factors becomes significant for long experiment times. In summary, the findings of this work can serve as guidelines for minimizing ECSA loss, e.g. by keeping the fuel cell in a benign operation regime via systems control
Jack Walton et al 2024 J. Electrochem. Soc.
Aluminum alloy, AlSi10Mg, prepared by selective laser melt (SLM) fabrication was anodized in 9.8 % sulfuric acid (Type II) at 15 V for a total of 23 min. Experiments were performed to study the potentiostatic anodization process and its effects on the oxide coating morphology, thickness, and electrochemical properties of the alloy. Prior to anodization, the alloy microstructure is composed of aluminum cells encapsulated in a silicon network. Anodizing the abraded and polished AlSi10Mg surface produced a porous oxide layer with a thickness of 5 μm. The oxide coating weight was 698 ± 29 mg/ft2. The oxide coating forms in the aluminum cells that are isolated from one another by the silicon phase. In electrochemical tests, the anodic and cathodic potentiodynamic polarization currents were suppressed by factors of 15× and 215×, respectively, as compared to the unanodized controls. The data indicate the anodic oxide coating suppresses the cathodic more than the anodic reaction rate. Linear polarization resistance (Rp) values increased by 279× after anodization. The corrosion current density values (jcorr) decreased by 133× after anodization. Taken together, the electrochemical data indicate the anodic oxide coating (unsealed) increases the corrosion resistance of the SLM alloy by two orders of magnitude.