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.
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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.
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.
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.
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.
Adam Z. Weber et al 2014 J. Electrochem. Soc. 161 F1254
Polymer-electrolyte fuel cells are a promising energy-conversion technology. Over the last several decades significant progress has been made in increasing their performance and durability, of which continuum-level modeling of the transport processes has played an integral part. In this review, we examine the state-of-the-art modeling approaches, with a goal of elucidating the knowledge gaps and needs going forward in the field. In particular, the focus is on multiphase flow, especially in terms of understanding interactions at interfaces, and catalyst layers with a focus on the impacts of ionomer thin-films and multiscale phenomena. Overall, we highlight where there is consensus in terms of modeling approaches as well as opportunities for further improvement and clarification, including identification of several critical areas for future research.
E. Peled and S. Menkin 2017 J. Electrochem. Soc. 164 A1703
The Solid-Electrolyte-Interphase (SEI) model for non-aqueous alkali-metal batteries constitutes a paradigm change in the understanding of lithium batteries and has thus enabled the development of safer, durable, higher-power and lower-cost lithium batteries for portable and EV applications. Prior to the publication of the SEI model (1979), researchers used the Butler-Volmer equation, in which a direct electron transfer from the electrode to lithium cations in the solution is assumed. The SEI model proved that this is a mistaken concept and that, in practice, the transfer of electrons from the electrode to the solution in a lithium battery, must be prevented, since it will result in fast self-discharge of the active materials and poor battery performance. This model provides [E. Peled, in "Lithium Batteries," J.P. Gabano (ed), Academic Press, (1983), E. Peled, J. Electrochem. Soc., 126, 2047 (1979).] new equations for: electrode kinetics (io and b), anode corrosion, SEI resistivity and growth rate and irreversible capacity loss of lithium-ion batteries. This model became a cornerstone in the science and technology of lithium batteries. This paper reviews the past, present and the future of SEI batteries.
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Timothy C. Hudak et al 2024 J. Electrochem. Soc. 171 053502
Redox-Electrodialysis (r-ED) is an electrochemical desalination cell architecture that has recently received considerable interest, due to its low energy demand relative to electrochemical desalination technologies that rely on electrode-based ion removal. To further improve the energy efficiency of r-ED, we developed a lumped mathematical model with no adjustable parameters to investigate the various sources of overpotential within the cell. Existing models of electrodialysis and r-ED cells either do not accurately incorporate all phenomena contributing to the overpotential or utilize empirical fitting parameters. The model developed here indicates that ohmic overpotentials, especially in the diluate chamber, are the most significant contributors to energy losses. Based on this insight, we hypothesized that adding an ion exchange resin wafer in the diluate compartment would increase the ionic conductivity and decrease the energy demand. Experimental results showed an 18% reduction in specific energy use while achieving the same degree of salt removal (20 mM to 12 mM). Furthermore, the resin wafer enabled complete desalination to potable drinking levels at a current density previously unachievable within practical operating voltage limits (4.93 mA cm−2). We also expanded the model to explore differences in r-ED energy use between configurations using multiple cells and a single cell with increased area.
Dong Jae Kang et al 2024 J. Electrochem. Soc. 171 050517
In this study, Li1.3Al0.3Ti1.7(PO4)3 (LATP)-based lithium metal battery (LMB) cells are prepared using two different protection layers against Li metal: a solid polymer electrolyte (SPE) containing polyethylene oxide and lithium bis(fluorosulfonyl)imide (LiTFSI), and a composite polymer electrolyte (CPE) filled with a 14 wt% Li6.4La3Zr1.4Ta0.6O12 (LLZTO). The CPE-containing symmetric cell exhibits a smaller overvoltage than that of its SPE-containing counterpart, which is maintained for ∼1000 h at 0.1 mA·cm−2 at 60 °C, owing to enhanced Li-ion transport in the CPE and at the LATP–CPE interface as well as the uniform Li deposition induced by the CPE with a higher Li+ transference number. Post-material analyses reveal that the CPE imparts long-term (∼1000 h) protection to the LATP against Li metal, whereas the SPE is effective over a shorter period (∼100 h). The CPE-based full cell exhibits a higher capacity (∼141 mAh·g−1; with a LiFePO4) and capacity retention (∼95%) than those of the SPE-based full cell (∼130 mAh·g−1 and ∼55%, respectively), for 310 cycles at 60 °C. This study recommends utilizing asymmetric solid electrolytes containing a ceramic (LATP at the cathode) and composite polymer (PEO + LLZTO at the anode) to improve cyclability and suppress Li dendrite growth in solid-state LMBs.
Yingde Huang et al 2024 J. Electrochem. Soc. 171 050516
Olivine-type lithium iron phosphate (LFP) is used widely as a cathode material with excellent cycling stability, thermal stability, and low cost for lithium-ion batteries in power vehicles and energy storage. However, it has inherent drawbacks that limit its further development, such as low electronic conductivity and lithium ion diffusion rate. Here, secondary spherical particles LFP-W/Ti@C were synthesized using a simple sanding and spray drying method. The pyrolysis of glucose forms a uniform and dense amorphous carbon on the surface of LFP, and the constructed three-dimensional conductive network accelerates the transfer of electrons and ions while mitigating the volume expansion during the lithiation-delithiation process. In addition, the synergistic co-doping of W/Ti achieves nanosizing of primary particles with more active sites providing locations for lithium ions storage, while reducing polarization and internal resistance and enhancing the diffusion kinetics of lithium ion. The LFP-W/Ti@C obtained after optimization still has a discharge capacity of 107.7 mAh g−1 (with a cycle retention rate of up to 100%) after 500 cycles at 5 C. This simple W/Ti co-doping strategy provides excellent rate performance and shows great potential for fast charging in electric vehicles.
Meng Yue et al 2024 J. Electrochem. Soc. 171 050515
N-methyl-2-pyrrolidone (NMP) is the most common solvent used in coating positive electrode materials on aluminum foil during the manufacturing of lithium-ion batteries. NMP is a strongly polar aprotic solvent that effectively dissolves the polyvinylidene difluoride binder. While the majority of NMP typically evaporates during the electrode baking process, trace amounts may persist, particularly in positive electrodes containing nano-sized and highly-porous active materials. We noted residual NMP in the positive electrodes of Li-ion pouch cells containing LiMn0.8Fe0.2PO4 due to the extremely high surface area of the material and we wanted to determine the impact of this residual NMP. Therefore, a control electrolyte was purposely spiked with varying amounts of NMP and used in NMC532/graphite pouch cells to investigate the impact of residual NMP on lithium-ion battery performance. Experimental results indicate that NMP has the potential not only to neutralize the electrolyte additive ethylene sulfate but also to independently increase cathode impedance, leading to a higher rate of capacity loss during charge-discharge cycling. It is crucial to establish the appropriate procedure for baking electrodes containing NMP, both in laboratory and industrial settings, to mitigate these effects.
Haomin Bai et al 2024 J. Electrochem. Soc. 171 050513
A multi-functional binder was designed for silicon-based anode lithium-ion battery to alleviate the huge volume expansion of silicon anode during the process of charging and discharging, and to provide ion transport channels to improve the rate performance of electrodes to meet the needs of rapid charging and discharging. In this study, a binder PAA-TUEG which combined the mechanical properties of PAA, the fast self-healing ability provided by the zigzag hydrogen bond in TUEG, and the ion transport ability provided by the ether-oxygen group was synthesized. The effect of different proportion of TUEG binder on the electrochemical performance of the electrode was further investigated. The synthesized PAA-TUEG5% polymer material exhibits a tensilestrength of 0.8 MPa and a fracture elongation of 397%. The Si@PAA-TUEG5% electrode demonstrates reversible capacities of 3035, 2260, and 1249 mAh g−1 at 0.5, 1, and 2 C (1 C = 3500 mAh g−1), respectively. In extended cycling tests, the remaining capacities after 180 cycles at 0.5 and 1 C are 852 and 793 mAh g−1, respectively. This innovative binder, featuring both self-healing ability and enhanced ion transport through dynamic reversible hydrogen bond and ionic bond, presents a promising design concept for the next generation of high-energy-density lithium-ion batteries.
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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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Sharma et al
Implications of rate coefficients, concentration ratio, and electron-transfer number of the redox species present in the anolyte and catholyte on the performance characteristics of a redox flow battery (RFB) were investigated. Toward this, a polyoxometalate (POM)-V4+/V5+ RFB (with order 104 of magnitude difference in their rate coefficients) was assembled by replacing the anolyte (V2+/V3+) of a well-established vanadium RFB (VRFB); the redox potential of POM is comparable to that of V2+/V3+. The performance of the POM-V4+/V5+ RFB improves by ~100 mV at reasonable operating current densities (~ 200 mA cm-2) as compared to that of a VRFB, in a 5 cm2 cell, even though the solubility of tungstosilicic acid (TSA) is 300 mM as compared to 1.8 M VOSO4. Only four electrons can be reversibly extracted from the POM, although extraction of 14 electrons (theoretical) is possible from TSA, limiting the charging voltage to 1.4 V. Overcharging leads to capacity loss and concentration ratio (Catholyte: Anolyte) impacts the overall performance of RFB. Significant vanadium crossover loss is also observed at the anode side.
Squires et al
Modelling lithium-ion battery behaviour is essential for performance prediction and design improvement. However, this task is challenging due to processes spanning many length scales, leading to computationally expensive models. Reduced order models have been developed to address this, assuming a "separation of scales" between micro- and macroscales. This study compares two approaches: direct microstructure-resolved 3D domain electrochemical modelling and a simplified 1D homogenized model, similar to the Doyle-Fuller-Newman model. 

The research investigates the validity of the scale separation assumption in continuum electrode-level models by varying scale separation factors, boundary conditions, and geometries. The findings reveal that in 3D models, more tortuous, less porous microstructures deviate more from 1D predictions, especially under higher discharge rates. However, under realistic conditions, with an electrode featuring eight particles across its thickness and typical transport properties, the 3D model predicts only a slight (2%) increase in current compared to the 1D model at a high rate of 7C (approximately 350 A/m²).

These results suggest that the separation of scales assumption in the DFN model is generally suitable for a wide range of operating conditions. However, 1D models may overlook local variations in electrolyte concentration and potential, crucial for understanding degradation mechanisms.
Nguyen et al
Aquaculture, driven by increasing demands for animal proteins and fats, faces multifaceted challenges stemming from environmental factors such as climate change and pollution, alongside issues like disease susceptibility and limited therapeutic tools. However, the emergence of nanotechnology (NNT) offers a promising solution across various aquaculture domains. Nano-enhanced feed has been shown to improve fish growth rates, while nanomaterials are reducing the treatment economy by effectively eliminating contaminants. Genetic manipulation methods combined with nanobiotechnology have revolutionized fish ancestry studies, with advancements such as nanosensors and DNA-based vaccines significantly impacting fish life and immune systems. Moreover, nanotechnology plays a crucial role in enhancing fish processing, enabling sterile packaging and precise flavoring. Utilizing fishery waste through bio-nano-engineering and green nanoparticles offers new post-harvesting practices. Despite ongoing exploration, NNT presents versatile applications, prospects, and challenges in aquaculture, as detailed in this review. This paper provides an in-depth analysis of current trends, challenges, and prospects of NNT applications in aquaculture.
Lu et al
AISI 1018 carbon steel exhibits intergranular attack in molten aluminum chloride. To explore grain boundary corrosion initiation and propagation, tests have been conducted on several iron-based alloys, heat treated to recrystallization temperature, and using molten aluminum chloride and its mixture with other molten chlorides environments. Pure iron, A106, and AISI 1018 carbon steel have been exposed to both pure aluminum chloride and ferric chloroaluminate melt in both their recrystallized and as-received, cold-worked conditions. Intergranular corrosion is observed in both 1018 and A106 carbon steels in all the salts whereas pure iron only shows pitting. Materials processing has varying effects on the corrosion depths of 1018 and A106 carbon steels. The grain boundary microchemistry of 1018 carbon steel is examined with in-situ fracture Auger spectroscopy where molybdenum and carbon segregation are found, and a mechanism is proposed to explain the present corrosion phenomenon.
Senthil Arumugam et al
In Li[Ni,Mn,Co]O2 (NMC) cathode materials, small changes in transition metal ratio and particle surface area can significantly impact capacity retention. To understand the combined effect of transition metal ratio and the particle surface area, we studied LiNi0.5Mn0.5-xCoxO2 (x = 0.1-0.3) particles with two different morphologies: dense, spherical particles and high-surface area aggregates. All compositions in this series contain the same percentage of Ni but have differing amounts of Ni2+ and Ni3+. While Ni2+ tends to induce anti-site defects predominantly in the bulk, Ni3+ promotes particle surface reconstruction, both of which negatively impact capacity retention. Upon cycling to 4.4 V for 100 cycles, we observe that particles of high surface area with high Ni3+ concentration undergo the most severe capacity degradation. However, high surface area particles with high proportion of anti-site defects undergo sluggish capacity fade. Overall, with 60% of Ni2+ and 40% of Ni3+, spherical NMC 532 particles endure the detrimental effects of anti-site defects and surface reconstruction, but neither too prominently and thus emerges as the best candidate among the studied samples. This study highlights the synergy between transition metal ratio and particle surface area and how it determines the properties of the NMC cathode materials.
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Timothy C. Hudak et al 2024 J. Electrochem. Soc. 171 053502
Redox-Electrodialysis (r-ED) is an electrochemical desalination cell architecture that has recently received considerable interest, due to its low energy demand relative to electrochemical desalination technologies that rely on electrode-based ion removal. To further improve the energy efficiency of r-ED, we developed a lumped mathematical model with no adjustable parameters to investigate the various sources of overpotential within the cell. Existing models of electrodialysis and r-ED cells either do not accurately incorporate all phenomena contributing to the overpotential or utilize empirical fitting parameters. The model developed here indicates that ohmic overpotentials, especially in the diluate chamber, are the most significant contributors to energy losses. Based on this insight, we hypothesized that adding an ion exchange resin wafer in the diluate compartment would increase the ionic conductivity and decrease the energy demand. Experimental results showed an 18% reduction in specific energy use while achieving the same degree of salt removal (20 mM to 12 mM). Furthermore, the resin wafer enabled complete desalination to potable drinking levels at a current density previously unachievable within practical operating voltage limits (4.93 mA cm−2). We also expanded the model to explore differences in r-ED energy use between configurations using multiple cells and a single cell with increased area.
Meng Yue et al 2024 J. Electrochem. Soc. 171 050515
N-methyl-2-pyrrolidone (NMP) is the most common solvent used in coating positive electrode materials on aluminum foil during the manufacturing of lithium-ion batteries. NMP is a strongly polar aprotic solvent that effectively dissolves the polyvinylidene difluoride binder. While the majority of NMP typically evaporates during the electrode baking process, trace amounts may persist, particularly in positive electrodes containing nano-sized and highly-porous active materials. We noted residual NMP in the positive electrodes of Li-ion pouch cells containing LiMn0.8Fe0.2PO4 due to the extremely high surface area of the material and we wanted to determine the impact of this residual NMP. Therefore, a control electrolyte was purposely spiked with varying amounts of NMP and used in NMC532/graphite pouch cells to investigate the impact of residual NMP on lithium-ion battery performance. Experimental results indicate that NMP has the potential not only to neutralize the electrolyte additive ethylene sulfate but also to independently increase cathode impedance, leading to a higher rate of capacity loss during charge-discharge cycling. It is crucial to establish the appropriate procedure for baking electrodes containing NMP, both in laboratory and industrial settings, to mitigate these effects.
Isaac Squires et al 2024 J. Electrochem. Soc.
Modelling lithium-ion battery behaviour is essential for performance prediction and design improvement. However, this task is challenging due to processes spanning many length scales, leading to computationally expensive models. Reduced order models have been developed to address this, assuming a "separation of scales" between micro- and macroscales. This study compares two approaches: direct microstructure-resolved 3D domain electrochemical modelling and a simplified 1D homogenized model, similar to the Doyle-Fuller-Newman model. 

The research investigates the validity of the scale separation assumption in continuum electrode-level models by varying scale separation factors, boundary conditions, and geometries. The findings reveal that in 3D models, more tortuous, less porous microstructures deviate more from 1D predictions, especially under higher discharge rates. However, under realistic conditions, with an electrode featuring eight particles across its thickness and typical transport properties, the 3D model predicts only a slight (2%) increase in current compared to the 1D model at a high rate of 7C (approximately 350 A/m²).

These results suggest that the separation of scales assumption in the DFN model is generally suitable for a wide range of operating conditions. However, 1D models may overlook local variations in electrolyte concentration and potential, crucial for understanding degradation mechanisms.
Matthias Riegraf et al 2024 J. Electrochem. Soc. 171 054504
The currently ongoing scale-up of high-temperature solid oxide electrolysis (SOEL) requires an understanding of the underlying dominant degradation mechanisms to enable continuous progress in increasing stack durability. In the present study, the degradation behavior of SOEL stacks of the type “MK35x” with chromium-iron-yttrium (CFY) interconnects and electrolyte-supported cells (ESC) developed at Fraunhofer IKTS was investigated. For this purpose, the initial electrochemical performance of a 10-cell stack was characterized in various operating conditions in both fuel cell and electrolysis mode. Degradation was evaluated during galvanostatic steady-state steam electrolysis operation for more than 3000 h at an oxygen side outlet temperature of 816 °C and a current density of −0.6 A cm−2 and showed an average voltage evolution rate of −0.3%/kh demonstrating high stability. Initial and final characterization at the part load operating point at −0.39 A cm−2 and 800 °C led to the determination of a positive overall degradation rate of 0.4%/kh showing a considerable impact of the operating conditions on the degradation rate. By means of electrochemical impedance spectroscopy analysis it was shown that the stack’s ohmic resistance increased whereas the polarization resistance decreased most likely due to an enhancement in LSMM’/ScSZ oxygen electrode performance.
Neeha Gogoi et al 2024 J. Electrochem. Soc. 171 050506
Vinylene carbonate (VC) is the most commonly applied performance-enhancing electrolyte additives in Li-ion batteries to date. Despite numerous studies, there is a lack of consensus regarding the various reaction pathways of VC and their implications. VC has primarily been observed to either polymerize forming poly(vinylene carbonate) (poly(VC)) or decompose releasing major amounts of CO2, two seemingly contradictory processes. Herein, we present evidence of additional reaction pathways of VC highlighting its role as a H2O scavenging agent. In contrast to the typical electrolyte solvent ethylene carbonate, VC reacts much more rapidly with water impurities, especially when in contact with hydroxides, forming products less likely to influence cell performance. Efficient removal of water and hydroxides is essential to preserve the stability of Li-ion electrolyte solvent and salt, hence guaranteeing a long lifetime of the battery. Model studies pinpointing reaction pathways of electrolytes and additives, as presented herein, are critical not only to improve modern Li-ion cells but also to establish design principles for future battery chemistries.
Debbie Zhuang et al 2024 J. Electrochem. Soc. 171 050510
Industry-standard diagnostic methods for rechargeable batteries, such as hybrid pulse power characterization (HPPC) tests for hybrid electric vehicles, provide some indications of state of health (SoH), but lack a physical basis to guide protocol design and identify degradation mechanisms. We develop a physics-based theoretical framework for HPPC tests, which are able to accurately determine specific mechanisms for battery degradation in porous electrode simulations. We show that voltage pulses are generally preferable to current pulses, since voltage-resolved linearization more rapidly quantifies degradation without sacrificing accuracy or allowing significant state changes during the measurement. In addition, asymmetric amounts of information gain between charge /discharge pulses are found from differences in electrode kinetic scales. We demonstrate our approach of physics-informed HPPC on simulated Li-ion batteries with nickel-rich cathodes and graphite anodes. Multivariable optimization by physics-informed HPPC rapidly determines kinetic parameters that correlate with degradation phenomena at the anode, such as solid-electrolyte interphase (SEI) growth and lithium plating, as well as at the cathode, such as oxidation-induced cation disorder. If validated experimentally, standardized voltage protocols for HPPC tests could play a pivotal role in expediting battery SoH assessment and accelerating materials design by providing new electrochemical features for interpretable machine learning of battery degradation.
Mark W. Verbrugge et al 2024 J. Electrochem. Soc. 171 050507
Our focus is on large-format lithium-ion batteries, used in electric vehicles today and in the foreseeable future, which are charged at high rates. In order to fully charge the battery, we employ a protocol often referred to as cc-cv (constant current followed by constant voltage). We compare and contrast results for cocurrent and countercurrent tab locations. We show how the pseudo three-dimensional (P3D) model can be used to assess temperature and current distributions and determine if Li plating is expected. We demonstrate the advantages of countercurrent tab locations to (i) obtain more uniform current and temperature distributions and (ii) lower the propensity for Li plating. Sensitivity analyses include the influence of ambient temperature and cell length. The methodology laid out in this work can facilitate rational battery-cell design and robust operation, including high-rate charging.
Louis Hartmann et al 2024 J. Electrochem. Soc.
The trend for increased nickel content in layered transition metal oxide cathode active materials and increasing charging cut-off voltages aggravates aging of lithium-ion battery cells at high state of charge (SOC). We investigate the calendaric aging behavior of large-format automotive prototype cells and laboratory single-layer pouch cells at high but realistic cell voltages/SOCs and demonstrate that electrolyte oxidation in combination with follow-up reactions can cause a significant loss of the LiPF6 salt in the electrolyte. For this, we analyze the LiPF6 concentration in aged cells, the generation of H2 upon storage, and the cell resistance for different aging conditions. We show that the LiPF6 loss is a critical aging phenomenon, as it cannot readily be detected by capacity fading measurements at low/medium C-rates or by cell resistance measurements, while it severely reduces rate and fast-charging capability. Under certain circumstances, LiPF6 loss can even lead to a temporary capacity increase due to conversion of the conducting salt in the electrolyte to cyclable lithium in the active material. Finally, we suggest a possible reaction mechanism and a simple accounting model to keep track of how different side reactions involved in LiPF6 loss change the cyclable lithium inventory of a lithium-ion cell.
Mingjie Tu et al 2024 J. Electrochem. Soc.
Silicon oxide (SiO) is a promising anode material for high-energy lithium-ion batteries, as it is made from low-cost precursors, has a potential close to that of Li, and has high theoretical specific capacity. However, the applications of SiO are limited by the intrinsic low electrical conductivity, large volume change, and low coulombic efficiency, which often lead to poor cycling performance. A common strategy to address these shortcomings is to blend SiO with graphite active materials to form a composite anode for better capacity retention. In this work, we derive a reduced order model (ROM1) using perturbation theory. We employ the multi-site, multi-reaction (MSMR) framework of a composite porous electrode blend consisting of two lithium-host materials, SiO and graphite. The ROM1 model employs a single-particle model (SPM) approach as the leading-order solution and involves the numerical analysis of a single, nonlinear partial differential equation for each host material that describes diffusion by means of irreversible thermodynamics, wherein chemical-potential gradients are the driving forces for the diffusion. The first-order correction treats losses other than that of the SPM.
Clifford M. Krowne 2024 J. Electrochem. Soc.
The Vanadium redox flow battery and other redox flow batteries have been studied intensively in the last few decades. The focus in this research is on summarizing some of the leading key measures of the flow battery, including state of charge (SoC), efficiencies of operation, including Coulombic efficiency, energy efficiency, and voltage efficiency, and energy density. New formulas are presented to allow calculation of energy density, under varying circumstances, including varying ionic electrolyte concentrations, terminal voltage, discharge times and cycle numbers, and electron exchange numbers in the redox chemical reactions. Effects of ionic crossover and side reactions are addressed, and it is shown which forms of energy density are robust against these additional undesirable chemical reactions.