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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.

 

The question of how soft polymers slide against hard surfaces is of significant scientific interest, given its practical implications. Specifically, such systems commonly show interesting stick–slip dynamics, wherein the interface moves intermittently despite uniform remote loading. The year 2021 marked the 50th anniversary of the publication of a seminal paper by Adolf Schallamach ( Wear , 1971), which first revealed an intimate link between stick–slip and moving detachment waves, now called Schallamach waves. We place Schallamach’s results in a broader context and review subsequent investigations of stick–slip, before discussing recent observations of solitary Schallamach waves. This variant is not observable in standard contacts so that a special cylindrical contact must be used to quantify its properties. The latter configuration also reveals the occurrence of a dual wave—the so-called separation pulse—that propagates in a direction opposite to Schallamach waves. We show how the dual wave and other, more general, Schallamach-type waves can be described using continuum theory and provide pointers for future research. In the process, fundamental analogues of Schallamach-type waves emerge in nanoscale mechanics and interface fracture. The result is an ongoing application of lessons learnt from Schallamach-type waves to better understand these latter phenomena. This article is part of the theme issue ‘Nanocracks in nature and industry’. 

Abstract Shear-based deformation processing by hybrid cutting-extrusion and free machining are used to make continuous strip, of thickness up to 1 mm, from low-workability AA6013-T6 in a single deformation step. The intense shear can impose effective strains as large as 2 in the strip without pre-heating of the workpiece. The creation of strip in a single step is facilitated by three factors inherent to the cutting deformation zone: highly confined shear deformation, in situ plastic deformation-induced heating, and high hydrostatic pressure. The hybrid cutting-extrusion, which employs a second die located across from the primary cutting tool to constrain the chip geometry, is found to produce strip with smooth surfaces (Sa < 0.4 μm) that is similar to cold-rolled strip. The strips show an elongated grain microstructure that is inclined to the strip surfaces—a shear texture—that is quite different from rolled sheet. This shear texture (inclination) angle is determined by the deformation path. Through control of the deformation parameters such as strain and temperature, a range of microstructures and strengths could be achieved in the strip. When the cutting-based deformation was done at room temperature, without workpiece preheating, the starting T6 material was further strengthened by as much as 30% in a single step. In elevated-temperature cutting-extrusion, dynamic recrystallization was observed, resulting in a refined grain size in the strip. Implications for deformation processing of age-hardenable Al alloys into sheet form, and microstructure control therein, are discussed.