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Zinc-Sponge Battery Electrodes that Suppress Dendrites
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Defect-Rich CoFe-Alloy with Engineered Carbon Support for High-Performance Rechargeable Zn-Air Batteries.

Geeta Pandurang Kharabe1,2, Sidharth Barik1,2, Arun Torris3

  • 1Physical & Materials Chemistry Division, CSIR-National Chemical Laboratory, Pune, Maharashtra, 411008, India.

Small (Weinheim an Der Bergstrasse, Germany)
|July 7, 2025
PubMed
Summary

A novel defect-rich cobalt-iron (CoFe) alloy catalyst on engineered carbon supports significantly enhances rechargeable zinc-air battery (RZAB) performance, demonstrating superior power density and cycling stability.

Keywords:
3D tomographyN‐dopingalloy encapsulated structuredevice demonstrationgrain boundariesoxygen reduction and evolution reactionsrechargeable zinc‐air battery

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Area of Science:

  • Materials Science
  • Electrochemistry
  • Energy Storage

Background:

  • Rechargeable zinc-air batteries (RZABs) are promising energy storage devices, but their efficiency is limited by cathode catalyst performance.
  • Developing advanced bifunctional electrocatalysts for both oxygen reduction (ORR) and oxygen evolution (OER) reactions is crucial for RZAB advancement.

Purpose of the Study:

  • To synthesize a defect-rich CoFe-alloy catalyst with an engineered carbon support for high-performance RZABs.
  • To investigate the structural, electronic, and electrochemical properties of the novel catalyst.
  • To evaluate the performance of RZABs utilizing the developed catalyst.

Main Methods:

  • Synthesis of a CoFe(2:1)/N-rGCNT catalyst via annealing graphene oxide, cobalt and iron acetate, and melamine.
  • Characterization of the catalyst's structure, including in situ formation of CoFe alloy-encapsulated CNTs and Fe-rich skin@CoFe alloy decorated NGr.
  • Electrochemical testing for ORR and OER activity, including onset potential, half-wave potential, and overpotential measurements.
  • 3D X-ray microtomography simulations to assess air permeability and gas diffusion.
  • Fabrication and testing of RZAB devices with the novel cathode.

Main Results:

  • The CoFe(2:1)/N-rGCNT catalyst exhibited excellent bifunctional activity with an ORR onset potential of 955 mV vs RHE, half-wave potential of 835 mV vs RHE, and OER overpotential of 340 mV (ΔE = 0.73 V).
  • Simulations indicated improved air permeability and gas diffusion due to the catalyst's structure.
  • RZABs with the CoFe(2:1)/N-rGCNT cathode achieved a peak power density of 171.3 mW cm⁻², outperforming a Pt/C-cathode.
  • The battery demonstrated a stable discharge profile at 10 mA cm⁻² with a specific capacity of 650 mAh g⁻¹Zn and 140 hours of high-rate cycling capability.

Conclusions:

  • The defect-rich CoFe-alloy catalyst with engineered carbon support offers superior electrocatalytic activity and enhanced RZAB performance.
  • The catalyst's unique structure, including line defects and improved conductivity, is key to its high performance.
  • This work presents a promising pathway for developing advanced cathode materials for efficient and durable rechargeable zinc-air batteries.