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A battery is a galvanic cell that is used as a source of electrical power for specific applications. Modern batteries exist in a multitude of forms to accommodate various applications, from tiny button batteries such as those that power wristwatches to the very large batteries used to supply backup energy to municipal power grids. Some batteries are designed for single-use applications and cannot be recharged (primary cells), while others are based on conveniently reversible cell reactions that...
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Tailoring Composite Microstructure Through Milling for Dry-Processed Sulfide-Based Solid-State Battery Cathodes.

Finn Frankenberg1, Carina A Heck1, Maximilian Kissel2

  • 1Technische Universität Braunschweig, Institute for Particle Technology, Volkmaroder Straße 5, 38104, Braunschweig, Lower Saxony, Germany.

Small (Weinheim an Der Bergstrasse, Germany)
|September 5, 2025
PubMed
Summary
This summary is machine-generated.

Mechanical processing significantly impacts solid-state battery cathode composites. Optimizing planetary ball milling enhances performance by controlling microstructure and heterocontacts, but excessive energy can be detrimental.

Keywords:
DEM simulationchemical process engineeringmicrostructureprocess–structure–propertysolid‐state battery

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Area of Science:

  • Materials Science
  • Electrochemistry
  • Chemical Engineering

Background:

  • Solid-state batteries (SSBs) are crucial for next-generation energy storage.
  • Composite cathodes, combining solid electrolytes and active materials, are key components of SSBs.
  • The influence of mechanical processing on SSB composite properties remains underexplored.

Purpose of the Study:

  • To investigate the impact of mechanical process parameters during planetary ball milling on Li6PS5Cl and LiNi0.83Co0.11Mn0.06O2 composite cathodes.
  • To understand how milling affects microstructure, particle size, and aggregate formation.
  • To correlate milling energy input with electrochemical performance.

Main Methods:

  • Planetary ball milling of Li6PS5Cl and LiNi0.83Co0.11Mn0.06O2.
  • Microstructural analysis (particle size, aggregate formation).
  • Discrete element simulations to model microstructure evolution.
  • Electrochemical performance testing.
  • Dry film production and analysis.

Main Results:

  • Milling significantly alters composite microstructure, affecting solid electrolyte particle size and electrolyte-active material aggregation.
  • Increased milling energy initially improves electrochemical performance by increasing heterocontact density.
  • Excessive milling energy negatively impacts performance due to decreased Li6PS5Cl crystallite size and increased LiNi0.83Co0.11Mn0.06O2 strain.
  • Dry film production can partially compensate for non-optimized milling, but precise control is paramount.

Conclusions:

  • Mechanical processing, specifically planetary ball milling, is a critical factor in determining the properties and performance of composite cathodes for SSBs.
  • Optimizing milling parameters is essential for maximizing electrochemical performance.
  • Understanding and controlling the interplay between milling energy, microstructure, and material properties is vital for advancing SSB technology.