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Robust Silicon-Based Anode with High Energy Density upon Dual Welding Encapsulation.

Wenhui Lai1, Jong Hak Lee2, Zhen Yuan Yeo3

  • 1Department of Material Science and Engineering, National University of Singapore, Singapore 117575, Singapore.

ACS Nano
|October 22, 2025
PubMed
Summary

Researchers developed a dual welding strategy for silicon anodes in lithium-ion batteries. This method enhances stability and suppresses volume expansion, enabling high energy density and stable cycling for commercial silicon batteries.

Keywords:
dual welding encapsulationlithium-ion batteriesmachine learningsilicon anodesspark plasma sintering

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Area of Science:

  • Materials Science
  • Electrochemistry
  • Nanotechnology

Background:

  • Silicon anodes offer high theoretical capacity for lithium-ion batteries.
  • Volume expansion and weak interfacial contact limit silicon anode practical application.
  • Structural instability arises from large volume changes during battery cycling.

Purpose of the Study:

  • To develop a novel dual welding encapsulation strategy for silicon anodes.
  • To enhance interfacial contact and structural stability of silicon anodes.
  • To investigate the underlying mechanisms using advanced characterization techniques.

Main Methods:

  • Constructing Si-C chemical bonds between silicon and carbon shells.
  • Establishing C-C interlayer bonding among carbon shells.
  • Utilizing machine-learning-enhanced transmission electron microscopy for interface analysis.

Main Results:

  • The dual welding mechanism significantly improves the mechanical strength of the carbon shell.
  • Sustained electrical connection is ensured via Si-C bonds, mitigating interfacial instability.
  • Volume expansion was suppressed below 12% after 300 cycles.
  • Full cells achieved a high energy density of 576 Wh kg⁻¹ with stable cycling.

Conclusions:

  • The dual welding strategy effectively addresses silicon anode instability.
  • This approach paves the way for the commercialization of high-performance silicon-based batteries.
  • The findings inspire new designs for robust anode materials in energy storage.