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Materials characterization solutions for battery research and manufacturing
Developing a detailed knowledge of the chemistry, morphology, and structure of battery materials is critical whether the goal is to develop new electrolyte chemistry or innovative electrode architecture, to reduce production costs, or to investigate the causes of battery failure to improve performance.
Our suite of microscopy and spectroscopy solutions allows you to probe elemental, chemical, and structural characteristics in exceptional detail, from the cell level down to the nano and atomic scales. The resulting material characterization insights enable confident, knowledge-led progress across the battery value chain, towards more economical operation and superior battery performance.
Battery research and development
Battery researchers rely on detailed understanding of structure-function relationships for efficient progress towards higher performance. This calls for reliable and detailed structural and chemical characterization on the one hand and rigorous assessment of the impact of change on the other.
Characterizing materials at the microstructural level in their native states, quantifying the impact of cycling on electrodes, and developing an in-depth understanding of behavior at the solid-electrolyte interface (SEI) are all key activities on the road to progress.
Battery researchers are some of the heaviest users of all our spectroscopy and microscopy instruments, including SEM, DualBeam FIB-SEM, TEM, and XPS. They value the ability to build detailed 2D and 3D models that extend from the cell level down to individual particle morphology and to characterize phase distribution, interfacial surface area, elemental distribution, connectivity, and tortuosity in sufficient detail to understand molecular transport within the cell and its impact. Powerful software maximizes the utility and value of measurements made at different scales, enabling presentation and visualization in ways that maximize data utility.
Cryo-STEM/EDS analysis of the cathode/solid electrolyte interface of a solid state battery. The lamella is prepared by Thermo Scientific IGST workflow. Zhang et. al, Chem. Commun., 2023,59, 4600-4603
Most battery materials are beam-sensitive and air-sensitive; therefore, they are challenging to characterize in their native states without proper protection during sample transfer and without a sound characterization strategy within the electron microscope and XPS.
The Thermo Scientific Inert Gas Sample Transfer (IGST) Workflow, with its combination of a DualBeam instrument and a TEM, provides a reliable and repeatable pathway to characterize battery materials in their native states all the way to nanometer scale. When you utilize the IGST Workflow, the characterization of the cathode-electrolyte interface (CEI) layer facilitates a thorough comprehension of the degradation process in all-solid-state batteries, guiding in the design and development of future generations of these batteries.
When you characterized the elemental and chemical states of the surface layers of a battery material via XPS (e.g., SEI comparison between fresh and cycled battery), the Thermo Scientific Vacuum Transfer Module (VTM) protects the battery electrode samples from air and moisture contamination during transfer from glove box to XPS for characterization.
XPS survey spectra from pristine (blue) and cycled cathode (red) samples. Used cathode sample is transferred via VTM between glovebox and XPS
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Battery quality control
The defining goal for battery manufacturers is to deliver products with consistent and well-defined performance at a competitive price. A better understanding of materials, production processes, and battery performance are the keys to achieving these goals. The need is for relevant information at the point of production to drive effective decision-making around raw material supply, process troubleshooting, failure analysis, and waste minimization. The battery industry is still demanding technological advancement with regard to the materials used and process optimization.
Raw material and electrode quality control (QC) are primary areas for the application of SEM, which enables the accurate detection of morphological abnormalities for morphology control and detection of alien particles and contaminants for impurity analysis. Similarly, contaminants and defects are a defining concern throughout, with manufacturers relying on relevant and detailed analysis to not only detect a problem but to provide the information needed to determine its root cause. A combination of SEM with an automated software solution is a powerful tool for QC in battery production.
Particle morphology analysis
By enhancing quality control in battery production, our solution streamlines the evaluation of cathode precursors and particles. The process involves size distribution measurement and surface structure analysis across various scales. Through automated SEM image analysis such as AutoScan Scripts and Thermo Scientific Phenom ParticleMetric Software, manual input time is significantly reduced, from hours to minutes, ensuring consistent, accurate data. This efficient approach safeguards cathode quality by verifying precursor particle granulometry and facilitates cost reduction by identifying and addressing precursors that do not meet QC criteria, allowing for recuperation and reprocessing.
Typical SEM imaging workflow compared to the automated workflow for particle morphology QC
Impurity analysis in battery materials
In the optimization of battery manufacturing, our solution addresses impurity challenges, especially those involving copper (Cu) and iron (Fe) metal impurity particles, minimizing the risk of short-circuiting or thermal runaway events. Traditional impurity detection methods are time-consuming and manual. Our approach integrates automated SEM analysis with Thermo Scientific Perception Software, ensuring rapid, accurate impurity detection across the manufacturing process. The system classifies particles based on morphology and composition, facilitating high throughput. You can efficiently assess impurity levels against specified criteria and comprehensive data, including particle images, mask images, positions, morphology details, and labeled spectra, which are recorded for thorough impurity analysis. The results are presented in accordance with ISO16232/VDA19 standards, contributing to increased yield and reduced scrap in battery production.
NMC cathode powder sample analyzed via Perception Software that shows particle information table of representative contaminants particles
Battery materials analysis webinars
Automated imaging analysis solution for battery QA/QC
Modern battery manufacturing includes a variety of challenges, including limited resources, the need to address an increasing number of tests impacting scrap rate, and ensuring that results are reproducible and reliable across operators and production sites. Thermo Scientific Avizo Trueput Software give you access to automated SEM imaging analysis for particle size distribution, cracked particle detection, particle binder/void/crack analysis, precursor primary structure analysis, and the post calendaring layer in the battery production environment. It enables consistent data interpretation, enhances productivity and efficiency, and also provides clear, straightforward pass/fail reports, supported by comprehensive data, to facilitate quick decision-making on the production floor.
Battery failure analysis
Problems in battery production can arise throughout the full manufacturing process, from raw material feeding through to cell assembly. Soldering, leakage, delamination, and non-uniformity issues are all routinely encountered, making failure analysis a crucial step. In-depth failure analysis is vital for manufacturers learning how to safeguard the highest levels of performance, while a detailed understanding of degradation and aging provides vital information for improving performance. Electron microscopy has a valuable role to play in elucidating the causes of failure, thereby enabling effective remedial action.
a) and b) CleanMill System-prepared NMC cathode sample cross-section that was transferred to the Apreo 2 SEM with the CleanConnect System. c) Cross-section of the NMC cathode prepared via the CleanMill System without protection from the CleanConnect System.
In enhancing battery manufacturing efficiency, our solutions revolutionize sample preparation with a focus on quality and speed. The importance of high-quality cross-sections for detailed electrode structure analysis is paramount for understanding battery cell failure. Conventional methods often introduce artifacts, hindering effective investigation. Our approach utilizes the Thermo Scientific CleanMill Broad Ion Beam System and the Thermo Scientific CleanConnect Sample Transfer System for full inert gas sample transfer, ensuring a protected environment. This combination enables rapid, high-quality surface preparation, minimizing manual input. With this advanced sample preparation, SEM unveils critical insights into layer thickness, particle size, crystallography, cracking, and porosity. Avoiding air contamination guarantees relevant data, enhancing the reliability of investigations and contributing to a more efficient and less time-consuming sample preparation process.
For Research Use Only. Not for use in diagnostic procedures.