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DOE OSTI2021

Efficient diffusion of superdense lithium via atomic channels for dendrite-free lithium–metal batteries

The non-uniform aggregation of fast-diffused Li on an anode surface would aggravate its tip-effect-induced nucleation/growth, leading to the notorious dendrite growth in Li metal batteries (LMBs). Tuning the Li diffusion on the anode surface has been regarded previously as a mainstream method to induce its uniform deposition, while the diffusion of Li in the anode bulk is usually ignored. In this study, conceptually different from the classic surface modification, we propose a molecular tunnelling strategy to construct atomic channels in graphite bulk, which enables the fast diffusion of superdense Li. Density functional theory calculations and ab initio molecular dynamics simulations prove that the bulk diffusion through atomic channels could become a new and dominating path. Its reversible and efficient diffusion has been further visualized by in situ transmission electron microscopy. As a result, when coupled with high-loading LiFePO 4 cathodes (20 mg cm –2 ), a high areal capacity and 100% capacity retention are achieved over 370 cycles. Through this work a new strategy is developed based on the bulk-diffusion of superdense Li for dendrite-free LMBs, which can be pervasive in other high-performance energy storage systems.

25 ENERGY STORAGE↗

DOE OSTI2017

Direct atomic-level insight into the active sites of a high-performance PGM-free ORR catalyst

Platinum group metal–free (PGM-free) metal-nitrogen-carbon catalysts have emerged as a promising alternative to their costly platinum (Pt)–based counterparts in polymer electrolyte fuel cells (PEFCs) but still face some major challenges, including (i) the identification of the most relevant catalytic site for the oxygen reduction reaction (ORR) and (ii) demonstration of competitive PEFC performance under automotive-application conditions in the hydrogen (H 2 )–air fuel cell. We demonstrate H 2 -air performance gains achieved with an iron-nitrogen-carbon catalyst synthesized with two nitrogen precursors that developed hierarchical porosity. In current densities recorded in the kinetic region of cathode operation, at fuel cell voltages greater than ~0.75 V, were the same as those obtained with a Pt cathode at a loading of 0.1 milligram of Pt per centimeter squared. The catalytic active site we proposed, carbon-embedded nitrogen-coordinated iron (FeN 4 ), was directly visualized with aberration-corrected scanning transmission electron microscopy, and the contributions of these active sites associated with specific lattice-level carbon structures were explored computationally.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2023

Low Impedance Cathode/Electrolyte Interfaces for High Energy Density Solid-State Batteries

All-solid-state batteries (ASSBs) using a ceramic fast Li-ion conductor as a solid-state electrolyte (SSE) have been proposed as a promising strategy to significantly increase the energy density of lithium batteries. Due to their high ion conductivity and excellent stability, Li-stuffed garnets exhibit the most promising physical and chemical properties for SSEs. However, the typical microstructure, thick (>100 μm) bulk electrolyte and simple planar electrode/electrolyte interfaces, combined with poor electrode wetting of the garnet result in excessively high area specific resistances (ASRs) that severely limit achievable current density and cell energy density. In this project, the team is building on their demonstrated expertise with garnet electrolytes and ASSBs to accomplish the following: (1) engineer interfaces to overcome high NMC/LLZ interfacial impedance and interfacial degradation; (2) develop processing and fabrication techniques to achieve high loading NMC/LLZ composite cathodes with low resistance and high cyclability; and (3) integrate the NMC/LLZ cathodes into all-solid-state Li-metal/LLZ cells to achieve high-energy-density batteries.

25 ENERGY STORAGE↗

DOE OSTI2020

Recent developments in catalyst-related PEM fuel cell durability

Cost and durability remain the two major barriers to the widespread commercialization of polymer electrolyte membrane fuel cell (PEMFC)-based power systems, especially for the most impactful but challenging fuel cell electric vehicle (FCEV) application. Commercial FCEVs are now on the road; however, their PEMFC systems do not meet the cost targets established by the U.S. Department of Energy, primarily due to the high platinum loading needed on the cathode to achieve the requisite performance and lifetime. Furthermore, while the activities of a number of commercial Pt-based alloy cathode catalysts exceed the beginning-of-life (BOL) targets, these activities, and the overall cathode performance, degrade via a variety of mechanisms described herein. Degradation is mitigated in current FCEVs by utilizing a cathode catalyst with a lower BOL activity (e.g., much lower transition metal alloy content and larger BOL nanoparticle size), necessitating higher catalyst loadings, and through the utilization of system controls that avoid conditions known to exacerbate degradation processes, such as limiting the fuel cell stack voltage range. The design and development of active and robust materials and eliminating the need for vehicle mitigation strategies would greatly simplify the operating system, allowing for greater transient operation, avoiding large hybridization, and curtailing of fuel cell power. Although system mitigation strategies have provided the near-term pathway for FCEV commercialization, material-specific solutions are required to further reduce costs and improve operability and efficiency. Future material developments should focus on stabilization of the electrode structure and minimization of the catalyst particle susceptibility to dissolution caused by oxide formation and reduction over PEMFC cathode-relevant operating potentials plus minimization of support corrosion. Ex situ accelerated stress tests have provided insight into the processes responsible for material and performance degradation and will continue to provide useful information on the relative stability of materials and benchmarks for robust and stable materials-based solutions not requiring system mitigation strategies to achieve adequate lifetime.

25 ENERGY STORAGE↗

DOE OSTI2017

Gel based sulfur cathodes with a high sulfur content and large mass loading for high-performance lithium–sulfur batteries

A significantly improved conductive matrix design for the sulfur electrode is essential to solve several problems related to sulfur electrochemistry toward the development of practical lithium–sulfur batteries (LSBs). Great progress has been made by using a variety of carbon-based nanostructures for physically and chemically confining soluble polysulfides as well as providing conductive paths. However, most of these electrode designs have a low sulfur content or a low sulfur loading, leading to a low specific capacity or low areal capacity at the electrode level. Herein, intrinsically N- and O-doped carbon nanoribbon (CNR) aerogels, obtained by pyrolysis of bacterial cellulose (BC) aerogels, were employed to form gel-based sulfur cathodes, simultaneously achieving both a high sulfur content and a high sulfur loading. With a sulfur loading of 6.4 mg cm−2 and a sulfur content of 90% at the whole electrode (including the current collector) level, a capacity as high as 943 mA h g−1 was achieved, which corresponds to an areal capacity of 5.9 mA h cm−2. The outstanding cell performance is attributed to the gel based cathode structure, which can strongly hold a large amount of the catholyte and relieve the shuttle effect of lithium polysulfides.

Li, Shiqi↗

DOE OSTI2019

Impedance Spectroscopy Characterization of PEM Fuel Cells with Fe-N-C-Based Cathodes

We report impedance spectroscopy analysis of PEM fuel cells built with platinum group metal-free (PGM-free) Fe-N-C cathodes with the catalyst loading and ionomer to catalyst ratio being variable parameters. The dependence of key cathode transport and kinetic parameters on the cell current density J are obtained in the range from 0.025 to 0.4 A cm -2 . The electrode performance is evaluated using the characteristic current densities for proton and oxygen transport in the cathode catalyst layer. Overall, certain electrode configurations demonstrate proton and oxygen transport properties comparable to those of Pt/C systems, making them promising substitutes for platinum at cathodic side of PEM fuel cells.

36 MATERIALS SCIENCE↗

DOE OSTI2023

Modeling Nanoscale Ohmics in Carbon Supports of Fuel Cell Cathodes

Here, reducing platinum (Pt) loading in polymer electrolyte fuel cells (PEFCs) while meeting performace requirements is critical to their widespread deployment. However, significant polarization losses manifest at higher current densities in cathodes with lower Pt content. The morphology of the carbon supports in PEFC cathodes affects the location of Pt deposition into the micropits or onto the surface of the carbon support, translating into different kinetic and transport resistances. In this work, we derive an agglomerate scale model that differentiates the sink terms for Pt on the surface and in the pits of carbon supports. We develop an approach to assess the impact of nanoscale ohmic resistance to Pt in the micropits arising from weakly ionic solution in the carbon support on PEFC performance. Effectiveness factors relating the actual reaction rate to the maximum reaction rate (had all the Pt been exposed) are derived and embedded into a one-dimensional catalyst layer model. Parameters in the catalyst layer model are tuned based on experimental local oxygen transport resistances. Subsequently, we estimate bounds for the micropore resistances based on geometric and physical arguments. Lastly, polarization curves are simulated to assess the effect of the micropore resistance in fully-humidified and oxygen-rich environments.

25 ENERGY STORAGE↗

DOE OSTI2025

Anion Exchange Membrane Water Electrolysis Using a Catalyst-Coated Membrane Cathode

A catalyst-coated membrane (CCM) approach to electrode fabrication for high pH water electrolysis offers enhanced interfacial contact between the catalyst layer and the membrane surface in comparison to the catalyst-coated substrate (CCS) electrode configuration. The CCM facilitates enhanced ionic and water transport between the cathode and the anion exchange membrane (AEM). This advantage is particularly significant with AEM water electrolysis (compared to proton exchange membrane water electrolysis) because the cathode typically operates under dry conditions and relies solely on diffusive water transport across the AEM from the liquid-fed anode. This study presents a direct performance comparison between CCS and CCM cathode configurations using identical hydrogen evolution reaction (HER) catalysts and other components. The use of a pseudo-reference electrode integrated into the membrane electrode assembly enabled detailed analysis of the CCM cathode polarization behavior. Surface characterization provided insight into the degradation mechanisms associated with the CCM configuration. Optimization of the cathode ionomer cross-link density improved both the cathode polarization performance and the electrolysis device durability. Further optimization of the HER catalyst loading in the CCM cathode resulted in additional gains in the electrolysis efficiency. Collectively, these findings offer valuable guidance for the design and fabrication of high-performance, durable AEM electrolysis CCMs.

Water electrolysis↗

DOE OSTI2025

The Role of Catholyte Modulation in Suppressing the Initial Capacity Fade of Zinc Electrolytic Manganese Dioxide Coin Cells

Despite its potential for zinc–manganese oxide batteries, electrolytic manganese dioxide (EMD) can experience capacity fade due to a deficiency in the Mn 2+ supply at the cathode electrolyte interphase (CEI) from side reactions, even in the presence of an electrolyte additive. In this work, electrolyte loading modulation at the cathode electrolyte interface (CEI) was correlated with Zn∥EMD cell capacity retention and cycling performance, as a proposed measure to curb the initial capacity fade observed in EMD. Initial galvanostatic charge/discharge cycling, with varied electrolyte loading, revealed severe capacity fade (from ~188 to 10 mAh g –1 for the highest loading of 200 μL) within the first 15 cycles. Such a decrease in cell capacity is correlated with the formation of a Mn 4+ deposit on the current collector and consequently, the Mn 2+ depletion at CEI, as was supported by elemental and Raman analyses. Interestingly, confinement of the electrolyte to the CEI at a lower (≤15 μL) electrolyte loading mitigated Mn 4+ side-deposition, maintaining the cell capacity at >80% over the first 15 cycles. Interfacial Mn supply/depletion could be monitored via voltammetric analysis based on changes of the Zn 2+ insertionreduction peak. Additional galvanostatic experiments corroborated the voltammetric interpretation and the proposed degradation pathway in the studied cell conditions. The outcomes of this work provide practical insight into coin-cell design and configuration strategies for developing Zn∥EMD batteries.

25 ENERGY STORAGE↗

DOE OSTI2016

A core–shell electrode for dynamically and statically stable Li–S battery chemistry

Sulfur is an appealing cathode material for establishing advanced lithium batteries as it offers a high theoretical capacity of 1675 mA h g -1 at low material and operating costs. However, the lithium–sulfur (Li–S) electrochemical cells face several formidable challenges arising from both the materials chemistry (e.g., low electrochemical utilization of sulfur and severe polysulfide diffusion) and battery chemistry (e.g., dynamic and static instability and low sulfur loadings). Here in this study, we present the design of a core–shell cathode with a pure sulfur core shielded within a conductive shell-shaped electrode. The new electrode configuration allows Li–S cells to load with a high amount of sulfur (sulfur loadings of up to 30 mg cm -2 and sulfur content approaching 70 wt%). The core–shell cathodes demonstrate a superior dynamic and static electrochemical stability in Li–S cells. The high-loading cathodes exhibit (i) a high sulfur utilization of up to 97% at C/20–C/2 rates and (ii) a low self-discharge during long-term cell storage for a three-month rest period and at different cell-storage conditions. Finally, a polysulfide-trap cell configuration is designed to evidence the eliminations of polysulfide diffusion and to investigate the relationship between the electrode configuration and electrochemical characteristics. Finally, the comprehensive analytical results based on the high-loading cathodes suggest that (i) the core–shell cathode is a promising solution for designing highly reversible Li–S cells and (ii) the polysulfide-trap cell configuration is a viable approach to qualitatively evaluating the presence or absence of polysulfide diffusion.

25 ENERGY STORAGE↗

DOE OSTI2025

3D printing of architected sulfur cathodes with dual-site atomic catalysts for accelerated polysulfide kinetics and Li-ion transport in high areal-loading lithium–sulfur batteries

The practical deployment of lithium–sulfur batteries (LSBs) is hindered by fundamental limitations in conventional slurry-cast cathodes, including poor sulfur utilization, sluggish ion transport, and low areal capacity, particularly in thick electrodes required for high energy density. To address these challenges, we present direct ink writing (DIW) as an additive manufacturing strategy to fabricate advanced current-collector-free, 3D-printed sulfur cathodes (3DP S@CoNi-DSACs/NC) with hierarchically porous architectures that enhance lithium-ion diffusion, promote electrolyte penetration, and reduce interfacial resistance. The synergistic effects of Co/Ni dual-atom sites accelerate redox kinetics and mitigate polysulfide shuttling. As a result, the optimized 3DP cathode with a sulfur loading of 5.4 mg cm −2 demonstrated excellent rate capability, delivering a high reversible capacity of 1041.4 mAh g −1 at 1C with 85.5% capacity retention after 1000 cycles, significantly outperforming its cast counterpart. Remarkably, even at a higher sulfur loading of 8.1 mg cm −2 , the 3DP cathode maintains outstanding performance, achieving a discharge capacity of 1538.4 mAh g −1 and an areal capacity of 12.5 mAh cm −2 at 0.1C. This study not only demonstrates the functional integration of catalytically active materials into 3D printable sulfur cathode architectures but also offers a scalable and transformative platform for building high-performance LSBs beyond conventional electrode manufacturing methods.

3D electrode↗

DOE OSTI2022

Unlocking Failure Mechanisms and Improvement of Practical Li-S Pouch Cells Through in Operando Pressure Study

For Lithium-sulfur (Li-S) battery commercialization, the study at a pouch cell level is essential, as some problems ignored or deemed minimal at the smaller level could have a greater effect on the performance of the larger pouch cell. Herein, the failure mechanisms of Li-S pouch cells are deeply investigated via in operando pressure analysis. It is found that highly porous structures of cathodes/separators and slow electrolyte diffusion through cathodes/separators can both lead to poor initial wetting. Additionally, Li-metal anode dominates the thickness variation of the whole pouch cell, which is verified by in situ measured pressure variation. Consequently, a real-time approach that combined normalized pressure with dP/dV analysis is proposed and validated to diagnose the morphology evolution of Li-metal anode. Moreover, applied pressure and porosity/tortuosity ratio of the cathode are both identified as independent factors that influence anode performance. In addition to stabilizing anodes, high pressure is proven to improve the cathode connectivity and avoid cathode cracking over cycling, which improves the possibility of developing cathodes with high sulfur mass loading. This work provides insights into Li-S pouch cell design (e.g., cathode and separator) and highlights pathways to improve cell capacity and cycling performance with applied and monitored pressure

25 ENERGY STORAGE↗

DOE OSTI2017

Analysis of alkaline exchange membrane fuel cells performance at different operating conditions using DC and AC methods

We report membrane electrode assemblies (MEAs) for anion exchange membrane fuel cells (AEMFCs) were manufactured from commercial materials: Pt/C catalyst, A201 AEM and AS4 ionomer by using an industrial mass-production digital printing method. The MEA designs selected are close to those recommended by US Department of Energy, including low loading of platinum on the cathode side (0.2 mg cm -2 ). Polarization curves and electrochemical impedance spectroscopy (EIS) were applied for MEA evaluation in fuel cell conditions with variation of gas humidification and oxygen partial pressure (air vs oxygen). The typical impedance curves recorded at H 2 /O 2 gas configuration consist of high- and medium-frequency arcs responsible for hydrogen oxidation and oxygen reduction, respectively. Operation with air as a cathode feed gas resulted in a decrease in AEMFC performance due to possible CO 2 poisoning and mass transfer losses. At the same time, EIS demonstrated formation of a low frequency loop due to diffusion limitations. Despite the low loading of platinum on the cathode (0.2 mg cm -2 ), a peak power density of ~330 mW cm -2 was achieved (at 50/50% of RH on anode and cathode), which is substantially higher performance than for AEMFC MEAs tested at similar conditions.

25 ENERGY STORAGE↗

DOE OSTI2019

Selenium Nanocomposite Cathode with Long Cycle Life for Rechargeable Lithium‐Selenium Batteries

Abstract Selenium (Se) is a potential cathode material for high energy density rechargeable lithium batteries. In this study, a binder‐free Se‐carbon nanotube (CNT) composite electrode has been prepared by a facile chemical method. At initial state, Se is present in the form of branched nanowires with a diameter of <150 nm and a length of 1–2 μm, interwoven with CNTs. After discharge and re‐charge, the Se nanowires are converted to nanoparticles embedded in the CNT network. This synthesis method provides a path for fabricating the Se cathodes with controllable mass loading and thickness. By studying the composite electrodes with different Se loading and thickness, we found that the electrode thickness has a critical impact on the distribution of Se during repeated cycling. Promising cycling performance was achieved in thin electrodes with high Se loading. The composite electrode with 23 μm thickness and 60 % Se loading shows a high initial capacity of 537 mAh g −1 and stable cycling performance with a capacity of 401 mAh g −1 after 500 cycles at 1 C rate. This study reports a synthesis strategy to obtain Se/CNT composite cathode with long cycle life for rechargeable Li−Se batteries.

Cui, Yi↗

DOE OSTI2018

Enabling High-Energy-Density Cathode for Lithium-Sulfur Batteries

High-loading sulfur electrode is critical for high energy Lithium-sulfur (Li-S) batteries used for practical applications. Unfortunately, dense and high-loading sulfur electrodes usually suffer from low sulfur utilization rate and limited cycle life. In this work, effects of electrode porosity on the electrode energy density, cell cycling stability, Li anode interface, and electrolyte/sulfur ratio were systematically investigated using high loading sulfur electrodes. The reduced electrode porosity increases volumetric energy density but also hinders electrode wetting process. To solve this problem, polysulfide (Li2S6) is selected as an electrolyte additive to enhance electrolyte penetration into dense sulfur cathodes. As a result, a high energy density of 1300 Wh L-1 (at electrode level) has been obtained for a dense sulfur cathode with a sulfur loading of 4 mg cm-2 at a compressed thickness of 60 µm. Li-S batteries with dense electrodes and Li2S6 additive also demonstrate promising cycling stability (~80 % capacity retention for 200 cycles). These significant improvements are contributed by synergistic effects of the dense sulfur cathode, improved electrolyte penetration, and suppressed growth of passivation layer on Li metal anode. This study sheds light on rational sulfur cathode structure design as well as control of electrode porosity for balanced energy density and cycling life.

Lu, Dongping↗

DOE OSTI2021

Unlocking Failure Mechanisms and Improvement of Practical Li–S Pouch Cells through In Operando Pressure Study

For Lithium-sulfur (Li-S) battery commercialization, the study at a pouch cell level is essential, as some problems ignored or deemed minimal at the smaller level could have a greater effect on the performance of the larger pouch cell. Herein, the failure mechanisms of Li-S pouch cells are deeply investigated via in operando pressure analysis. It is found that highly porous structures of cathodes/separators and slow electrolyte diffusion through cathodes/separators can both lead to poor initial wetting. Additionally, Li-metal anode dominates the thickness variation of the whole pouch cell, which is verified by in situ measured pressure variation. Consequently, a real-time approach that combined normalized pressure with dP/dV analysis is proposed and validated to diagnose the morphology evolution of Li-metal anode. Moreover, applied pressure and porosity/tortuosity ratio of the cathode are both identified as independent factors that influence anode performance. In addition to stabilizing anodes, high pressure is proven to improve the cathode connectivity and avoid cathode cracking over cycling, which improves the possibility of developing cathodes with high sulfur mass loading. Here, this work provides insights into Li-S pouch cell design (e.g., cathode and separator) and highlights pathways to improve cell capacity and cycling performance with applied and monitored pressure.

25 ENERGY STORAGE↗

DOE OSTI2018

Vertical Co 9 S 8 hollow nanowall arrays grown on a Celgard separator as a multifunctional polysulfide barrier for high-performance Li–S batteries

Lithium–sulfur (Li–S) batteries have been regarded as one of the most promising next-generation energy-storage devices, due to their low cost and high theoretical energy density (2600 W h kg -1 ). However, the severe dissolution of lithium polysulfides (LiPSs) and the fatal shuttle effect of the sulfur cathode seriously hinder the practical applications of Li–S batteries. To address such issues, we present here, for the first time, a novel metal organic framework (MOF)-derived Co 9 S 8 nanowall array with vertical hollow nanoarchitecture and high electrical conductivity, which is grown in situ on a Celgard separator (Co 9 S 8 –Celgard) via a feasible and scalable liquid-reaction approach, as an efficient barrier for LiPSs in Li–S batteries. Benefiting from the direct in situ growth of vertical Co 9 S 8 hollow nanowall arrays as a multifunctional polar barrier, the Co 9 S 8 –Celgard separator possesses large surface area, excellent mechanical stability, and particularly strong LiPS-trapping ability via chemical and physical interactions. With these advantages, even with a pure sulfur cathode with a high sulfur loading of 5.6 mg cm -2 , the Li–S cells with the Co 9 S 8 –Celgard separator exhibit outstanding electrochemical performance: the initial specific capacity is as high as 1385 mA h g -1 with a retention of 1190 mA h g -1 after 200 cycles. The cells deliver a high capacity of 530 mA h g -1 at a 1C rate (1675 mA g -1 ) even after an impressive number of 1000 cycles with an average capacity fade of only 0.039% per cycle, which is promising for long-term cycling application at high charge/discharge current densities, and pouch-type Li–S cells with the Co 9 S 8 –Celgard separator display excellent cycling performance. When the optimized cathode with the sulfur loading in well-designed yolk–shelled carbon@Fe 3 O 4 (YSC@Fe 3 O 4 ) nanoboxes is employed, the cell with Co 9 S 8 –Celgard delivers a high initial capacity of 986 mA h g -1 at a 1C rate with a capacity retention as high as 83.2% even after a remarkable number of 1500 cycles. In conclusion, this work presents a strategy to grow on the separator a multifunctional polar interlayer with unique nanoarchitecture and high conductivity to chemically and physically trap the LiPSs, thus significantly enhancing the performance of Li–S batteries.

25 ENERGY STORAGE↗

DOE OSTI2022

Artificial cathode electrolyte interphase for improving high voltage cycling stability of thick electrode with Co-free 5 V spinel oxides

Spinel-type cathode LiNi 0.5 Mn 1.5 O 4 (LNMO) has intrigued the transportation industry due to its high operating voltage and total elimination of the expensive cobalt element. However, LNMO cathode with high mass loading (> 3 mAh/cm 2 in areal capacity) has suffered from excessive capacity degradation upon long cycling. Here, a robust Al 2 O 3 surface layer is introduced to the thick LNMO electrode via atomic layer deposition (ALD). The capacity retention in full cells with the graphite anode is improved from 46.3% to 75.3% after 300 cycles with cutoff voltage up to 4.85 V, while enabling average Coulombic efficiency of 99.9% during the cycling. The post-mortem analyses reveal that the Al 2 O 3 surface layer would convert to Al-O-F /Al-F species upon cycling, offering stable interphase to protect the cathode material. Furthermore, these results demonstrate the significance of surface modification enabling high voltage cathode for next-generation LIBs.

25 ENERGY STORAGE↗