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Additive manufacturing of solid-state batteries is advantageous for improving the power density by increasing the geometric complexity of battery components, such as electrodes and electrolytes. In the present study, bulk three-dimensional Li_1+xAl_xTi_2−x(PO₄)₃(LATP) electrolyte samples were prepared using the laser powder bed fusion (L-PBF) additive manufacturing method. Li₃PO₄(LPO) was added to LATP to compensate for lithium vaporization during processing. Chemical compositions included 0, 1, 3, and 5 wt. % LPO. Resulting ionic conductivity values ranged from 1.4 × 10⁻⁶–6.4 × 10⁻⁸S cm⁻¹, with the highest value for the sample with a chemical composition of 3 wt. % LPO. Microstructural features were carefully measured for each chemical composition and correlated with each other and with ionic conductivity. These features and their corresponding ranges include: porosity (ranging from 5% to 19%), crack density (0.09–0.15 mm mm⁻²), concentration of residual LPO (0%–16%), and concentration and Feret diameter of secondary phases, AlPO4 (11%–18%, 0.40–0.61µm) and TiO2 (9%–11%, 0.50–0.78). Correlations between the microstructural features and ionic conductivity ranged from −0.88 to 0.99. The strongest negative correlation was between crack density and ionic conductivity (−0.88), confirming the important role that processing defects play in limiting the performance of bulk solid-state electrolytes. The strongest positive correlation was between the concentration of AlPO4 and ionic conductivity (0.99), which is attributed to AlPO4 acting as a sintering aid and the role it plays in reducing the crack density. Our results indicate that additions of LPO can be used to balance competing microstructural features to design bulk three-dimensional LATP samples with improved ionic conductivity. As such, refinement of the chemical composition offers a promising approach to improving the processability and performance of functional ceramics prepared using binderless, laser-based additive manufacturing for solid-state battery applications.

 

The rocksalt structured (Co,Cu,Mg,Ni,Zn)O entropy-stabilized oxide (ESO) exhibits a reversible phase transformation that leads to the formation of Cu-rich tenorite and Co-rich spinel secondary phases. Using atom probe tomography, kinetic analysis, and thermodynamic modeling, we uncover the nucleation and growth mechanisms governing the formation of these two secondary phases. We find that these phases do not nucleate directly, but rather they first form Cu-rich and Co-rich precursor phases, which nucleate in regions rich in Cu and cation vacancies, respectively. These precursor phases then grow through cation diffusion and exhibit a rocksalt-like crystal structure. The Cu-rich precursor phase subsequently transforms into the Cu-rich tenorite phase through a structural distortion-based transformation, while the Co-rich precursor phase transforms into the Co-rich spinel phase through a defect-mediated transformation. Further growth of the secondary phases is controlled by cation diffusion within the primary rocksalt phase, whose diffusion behavior resembles other common rocksalt oxides.

Graphical abstract

 

Entropy‐stabilized oxide (ESO) research has primarily focused on discovering unprecedented structures, chemistries, and properties in the single‐phase state. However, few studies discuss the impacts of entropy stabilization and secondary phases on functionality and in particular, electrical conductivity. To address this gap, electrical transport mechanisms in the canonical ESO rocksalt (Co,Cu,Mg,Ni,Zn)O are assessed as a function of secondary phase content. When single‐phase, the oxide conducts electrons via Cu⁺/Cu²⁺small polarons. After 2 h of heat treatment, Cu‐rich tenorite secondary phases form at some grain boundaries (GBs), enhancing grain interior electronic conductivity by tuning defect chemistry toward higher Cu⁺carrier concentrations. 24 h of heat treatment yields Cu‐rich tenorite at all GBs, followed by the formation of anisotropic Cu‐rich tenorite and equiaxed Co‐rich spinel secondary phases in grains, further enhancing grain interior electronic conductivity but slowing electronic transport across the tenorite‐rich GBs. Across all samples, the total electrical conductivity increases (and decreases reversibly) by four orders of magnitude with heat‐treatment‐induced phase transformation by tuning the grains’ defect chemistry toward higher carrier concentration and lower migration activation energy. This work demonstrates the potential to selectively grow secondary phases in ESO grains and at GBs, thereby tuning the electrical properties using microstructure design, nanoscale engineering, and heat treatment, paving the way to develop many novel materials.

 

Abstract High-entropy oxides (HEO) with entropic stabilization and compositional flexibility have great potential application in batteries and catalysis. In this work, HEO thin films were synthesized by pulsed laser deposition (PLD) from a rock-salt (Co 0.2 Ni 0.2 Cu 0.2 Mg 0.2 Zn 0.2 )O ceramic target. The films exhibited the target’s crystal structure, were chemically homogeneous, and possessed a three-dimensional (3D) island morphology with connected randomly shaped nanopores. The effects of varying PLD laser fluence on crystal structure and morphology were explored systematically. Increasing fluence facilitates film crystallization at low substrate temperature (300 °C) and increases film thickness (60–140 nm). The lateral size of columnar grains, islands (19 nm to 35 nm in average size), and nanopores (9.3 nm to 20 nm in average size) increased with increasing fluence (3.4 to 7.0 J/cm 2 ), explained by increased kinetic energy of adatoms and competition between deposition and diffusion. Additionally, increasing fluence reduces the number of undesirable droplets observed on the film surface. The nanoporous HEO films can potentially serve as electrochemical reaction interfaces with tunable surface area and excellent phase stability. Graphical abstract 

The quality of parts fabricated with additive manufacturing is influenced by the flowability of the feedstock particles, which is the result of many factors, including chemistry (e.g., true density, the presence of surface oxides, and impurities), morphology (e.g., particle shape and the presence of satellites), and particle size distribution. This work investigates the relationship between powder characteristics and flow behavior of different powders using three flowability testing methods. Six powders of two compositions (316L stainless steel and AlSi10Mg), made using two different methods (gas‐ and water‐atomization), are investigated to rationalize the effect of powder chemistry and morphology on flow behavior. The results show that the true density of the powders can influence several flowability metrics. In addition, aspect ratio strongly influences the initiation of flow from a static condition, whereas average particle size strongly dictates the ease of maintaining that flow.