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Batteries and Fuel Cells03:12

Batteries and Fuel Cells

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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Solid-state Graft Copolymer Electrolytes for Lithium Battery Applications
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Cold-Sprayed NMC622 Composite as a Cathode for Lithium-Ion Batteries.

Eunjeong Kim1, Alejandro Gallegos Tovar2, Erika P Ramos1

  • 1Lawrence Livermore National Laboratory (LLNL), Livermore, California 94550, United States.

ACS Applied Materials & Interfaces
|November 21, 2025
PubMed
Summary
This summary is machine-generated.

Cold-spray deposition offers a solvent-free method for creating lithium-ion battery cathodes, reducing energy use in electric vehicle battery manufacturing. This dry process shows promise for scalable and efficient electrode production.

Keywords:
CFD simulationNMC622cold sprayelectrochemical performancelithium-ion batterysolvent-free electrode fabrication

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Area of Science:

  • Materials Science
  • Electrochemistry
  • Chemical Engineering

Background:

  • Growing demand for high-energy, low-cost lithium-ion batteries (LIBs) for electric vehicles (EVs).
  • Conventional slurry casting and drying methods for battery cathodes are energy-intensive and face scalability challenges.

Purpose of the Study:

  • To investigate cold-spray (CS) deposition as a solvent-free fabrication method for LiNi0.6Mn0.2Co0.2O2 (NMC622) composite cathodes.
  • To evaluate the effects of CS process parameters on cathode morphology, density, and electrochemical performance.

Main Methods:

  • Utilized cold-spray deposition to create NMC622 composite cathodes using powder blends of NMC622, PVDF, and CB.
  • Investigated the impact of gas temperature, pressure, and standoff distance on deposit characteristics.
  • Employed computational fluid dynamics (CFD) simulations to analyze spray behavior.
  • Characterized cathode microstructure using X-ray diffraction (XRD).

Main Results:

  • Cold-spray deposition produced dense NMC622 cathode microstructures without phase changes.
  • Electrochemical performance showed initial capacities of ~96 mAh g⁻¹ (single-crystal NMC622) and ~167 mAh g⁻¹ (polycrystalline NMC622).
  • CFD simulations indicated increased particle velocity and reduced radial mass concentration with higher gas temperatures.

Conclusions:

  • Cold-spray deposition is a viable solvent-free technique for fabricating integrated cathode coatings.
  • The process offers a promising pathway for scalable, energy-efficient dry electrode manufacturing for next-generation LIBs.
  • CS-deposited cathodes demonstrate competitive performance compared to tape-cast samples, despite lower initial capacities than state-of-the-art slurry-cast methods.