Single‐Step Deformation Processing of Ultrathin Lithium Foil and Strip

Next‐generation, high‐efficiency energy storage and conversion systems require development of lithium metal batteries. But the high cost of production and constraints on thickness of lithium (anode) foils continue to limit adoption for integration into battery cell architectures. Here, a novel lithi...

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Bibliographic Details
Published in:Advanced materials technologies 2024-02, Vol.9 (4), p.n/a
Main Authors: Mohanty, Debapriya P., Mann, James B., Payathuparambil, Vijayakumar Niranjan, Baruah, Sweta, Román‐Kustas, Jessica K., Kustas, Andrew B., Sugihara, Tatsuya, Trumble, Kevin P., Chandrasekar, Srinivasan
Format: Article
Language:English
Subjects:
Anodes
Cutting
Energy efficiency
Foil
Lithium batteries
Machining
POWER TRANSMISSION AND DISTRIBUTION
Sheet metal
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Summary:Next‐generation, high‐efficiency energy storage and conversion systems require development of lithium metal batteries. But the high cost of production and constraints on thickness of lithium (anode) foils continue to limit adoption for integration into battery cell architectures. Here, a novel lithium anode manufacturing solution is demonstrated – single‐step production of ultrathin gauge foil formats directly from solid ingot. Hybrid cutting‐based deformation processes, involving large plastic strains and strain rates, produce foil to sub‐10 µm thickness, with surface quality even superior to present Li anode processing routes. Energy analysis shows the single‐stage processing is ≈50% more efficient than conventional processing by extrusion‐rolling. Through in situ force measurements and high‐speed imaging of the cutting it also characterize – for the first time – the flow stress of Li to strain rates of 800 sec−1, revealing a power‐law relationship. The results present a paradigm shift in manufacturing and integration of solid lithium anodes for energy applications. An innovative cutting‐based process is demonstrated that can produce ultrathin lithium (anode) foil directly from solid ingot at potentially low‐cost. The process is single‐step, employs compact infrastructure, can be implemented at point‐of‐use of foil, and requires 50% less energy than current conventional rolling‐extrusion. The work shall open new opportunities in production of solid‐state lithium batteries for next‐generation energy systems.
ISSN:2365-709X
2365-709X
DOI:10.1002/admt.202301315