Shengming
Zhang
a,
Bingkun
Hu
a,
Zeyang
Geng
b,
Xiangwen
Gao
ac,
Dominic
Spencer-Jolly
ad,
Dominic L.R.
Melvin
a,
Ziyang
Ning
a,
Guanchen
Li
be,
Max
Jenkins
a,
Longlong
Wang
a,
Hui
Gao
a,
Shengda D.
Pu
a,
T. James
Marrow
a,
Charles W.
Monroe
*b and
Peter G.
Bruce
*af
aDepartment of Materials, University of Oxford, Oxford, UK. E-mail: peter.bruce@materials.ox.ac.uk
bDepartment of Engineering Science, University of Oxford, Oxford, UK. E-mail: charles.monroe@eng.ox.ac.uk
cFuture Battery Research Center, Global Institute of Future Technology, Shanghai Jiao Tong University, Shanghai, China
dSchool of Metallurgy and Materials, University of Birmingham, Pritchatts Road, Birmingham, UK
eJames Watt School of Engineering, University of Glasgow, Glasgow, UK
fDepartment of Chemistry, University of Oxford, Oxford, UK
First published on 26th January 2024
Contouring or structuring of the lithium/ceramic electrolyte interface and therefore increasing its surface area has been considered as a possible strategy to increase the charging current in solid-state batteries without lithium dendrite formation and short-circuit. By coupling together lithium deposition kinetics and the me chanics of lithium creep within calculations of the current distribution at the interface, and leveraging a model for lithium dendrite growth, we show that efforts to avoid dendrites on charging by increasing the interfacial surface area come with significant limitations associated with the topography of rough surfaces. These limitations are sufficiently severe such that it is very unlikely contouring could increase charging currents while avoiding dendrites and short-circuit to the levels required. For example, we show a sinusoidal surface topography can only raise the charging current before dendrites occur by approx. 50% over a flat interface.
Broader contextUnlocking the potential of the lithium metal anode for solid-state batteries is key to realising solid state batteries with energy densities exceeding lithium-ion batteries used today. However, on charging such solid-state cells they suffer from lithium dendrite growth, leading to short-circuits and cell failure. This is one of the biggest problems facing solid state batteries. Increasing the surface area between the lithium metal anode and solid electrolyte by contouring the interface could lower the local current densities compared with a flat interface, helping to avoid dendrite growth. Herein, we used 3D printing to form contoured solid electrolytes with different topographies, peak separations and heights. We find the limitations due to inhomogeneous current distribution across the contoured (rough) surface quickly outweighs the benefit of increasing surface area between the lithium metal anode and solid electrolyte. Only a 50% improvement in critical charging current before dendrites occur can be achieved compared with a flat interface. As a result, contouring is unlikely to solve the dendrite problem in lithium anode solid state batteries. |
Here we consider the different factors that influence the critical current for dendrite formation when the Li/electrolyte interface is periodically contoured. Employing 3D printing to form a contoured solid electrolyte surface, we found that 3D bisinusoidal (commonly known as “egg-box”) interfacial shapes have the highest critical current for dendrites compared to other periodic topographies, specifically square pyramids and frustums of square pyramids. Using egg-box interfaces with different combinations of peak height and peak separation, we show that it is necessary to include the interfacial reaction kinetics of lithium deposition and the stress arising from lithium flow in the mechanistic picture. By examining how the local kinetics of lithium deposition and flow-induced surface stress/pressure are distributed across the interface, and by linking these distributions to a model for lithium dendrite growth,37 we rationalise how the critical current for dendrites varies with the topography of the contoured Li/electrolyte interfaces. Contouring increases the critical current for dendrite formation by increasing the interfacial surface area, but the increase is almost entirely suppressed by kinetic effects, severely limiting the extent to which the critical current can be increased by contouring. For example, a sinusoidal surface topography can only raise the charging current without dendrites by approx. 50% compared with a flat interface. It is very unlikely that contouring or shaping of the metal/solid electrolyte interface will solve the problem of increasing the charging current of solid-state batteries with a lithium metal anode without dendrite penetration.
Scanning electron microscopy (SEM) images showing the top-down planar view of the solid electrolyte with frustums of square pyramids, egg-box, and square pyramidal contoured surfaces before applying the Li metal and X-ray computed tomography (XCT) virtual cross-sectional views of the interface with the lithium metal in place are shown in Fig. 1a and b respectively. Fig. 1c shows simulations of the frustums of square pyramids, egg-box and square pyramidal contoured surfaces from an off-axis angle. The critical current for dendrites was determined by the voltage drop (2 mV) during plating, as described in Methods and Fig. S4 (ESI†), for each of the three differently contoured topographies shown in Fig. 1d. The voltage drops due to greater Li/solid electrolyte interfacial area and hence lower polarisation when dendrites penetrate the ceramic. It is also worth noting that the critical current for dendrites can be lower after long-term cycling due to voiding on stripping.21 Here we are considering the intrinsic limits due to contouring, as observed on the first plating. All the cells were measured under stack pressure of 7 MPa. Upon contact with a lithium metal anode, the thickness of interphase formed between Li6PS5Cl and lithium metal would typically reach at most 250 nm.38,39 A thin interphase would not contribute to any major inhomogeneity compare to the feature sizes of contoured surfaces, e.g. 900 to 10 μm. All the trapezoid waves, cosine waves and triangle waves in the cross sections of the frustums of square pyramids, egg-box, and square pyramids respectively, have the same peak height (H) of 25 μm and peak separation (S) of 150 μm, abbreviated as H25S150. Also plotted in Fig. 1d are the ratios of the total surface area of the Li/electrolyte interface to the geometrical area (area of cell cross-section), from which it is apparent that the variation of critical current for dendrites cannot be explained solely by changes in the surface area at the interface (surface roughness).
The calculated current density distributions across the interfaces for each of the three contoured topographies are shown in Fig. 1e. This is the current distribution due to the contoured shape of the interface alone, and is found by treating the electrolyte as a resistor with constant potential boundary conditions at the interfaces where it contacts Li – i.e., assuming that there is no interfacial resistance. The detailed calculation is described in S2 (ESI†). Local current densities scale with the geometrical current density and the former can be substantially higher than the latter. A geometrical current density of 1 mA cm−2 was used for the calculations in Fig. 1e. Currents are greatest at the bottoms of the troughs as viewed in Fig. 1e (i.e., at the farthest protrusions of Li metal into the Argyrodite) in each case. The maximum local current densities vary widely with contour type, emphasizing that local currents are highly morphology dependent, even on periodic surfaces with identical peak heights and peak separations. Importantly, the locations where local current density is highest represent the most likely sites for dendrite initiation, i.e. the local currents at these locations determine the values of the critical current for dendrites.40 The general observed trend in the critical currents for dendrites across contour types loosely correlates with the trend in these current maxima, but the large numerical difference between the simulated maxima for the frustums of square pyramids and egg-box surfaces is not reflected in the critical current for dendrites, suggesting that the current-distribution calculations in Fig. 1e do not suffice to explain how contour topography affects the critical current for dendrites.
To investigate how changes in the dimensions of structural features affect the critical current for dendrites, a series of egg-box contoured surfaces were prepared in which the height and separation of the peaks were varied systematically. The experimentally determined critical currents for dendrites for simultaneously varying peak heights (H) and separations (S) that maintain a fixed ratio of peak height to separation (H/S) are presented in Fig. 2a. The current distribution across the interface is invariant when H and S are changed at a fixed H/S, as reflected in the calculated local current maxima being invariant as shown in Fig. 2b. However, the experimentally determined critical currents for dendrites do vary for different combinations of peak height and peak separation with the same H/S, in accord with the observation that the current distribution in Fig. 1e cannot solely explain how the critical current for dendrites varies.
The current density distributions across the interface in Fig. 1e and Fig. 2b do not account for the kinetics of lithium deposition, which generally lead to surface overpotential.41 A linearized kinetic expression based on Butler–Volmer kinetics was coupled into the model to calculate how this affects the current density distribution across the Li/electrolyte interface, see S2 (ESI†) for details. The local current density distribution including the effect of kinetics was calculated for a geometrical current density of 1 mA cm−2. The calculated maxima extracted for the different surfaces are shown in Fig. 2c. By including the kinetics of Li deposition in the calculation of current distribution, the maximum local current density increases with an increase in the peak height and separation at a fixed H/S ratio. The increase in this maximum local current implies a decrease in the critical current for dendrites, in accord with the trend seen in Fig. 2a. It has been suggested that the intrinsic kinetics of Li deposition at the interface can be very fast.42–44 However, where interfacial kinetics are finite they play an important role in determining the local current density distribution, and therefore how the critical current for dendrites varies for contoured surfaces with constant H/S ratio.
Varying the H/S ratio impacts the current density distribution. Fig. 3 presents experimentally determined critical currents for dendrites as well as the calculated maximum current density for a series of egg-box surfaces with varying H/S, specifically with varying peak heights at a fixed separation of 150 μm (Fig. 3a–c) and varying peak separations at a fixed peak height of 25 μm (Fig. 3d–f). As the peak height increases at fixed peak separation or peak separation decreases at fixed peak height (i.e., as the H/S ratio increases at constant S or H), the experimental critical currents for dendrites pass through a maximum and then start to decrease. As shown in Table S1 (ESI†), the interfacial area for an egg-box interface increases monotonically as its H/S ratio increases, further proving that a simple surface area scaling cannot explain the trend of critical current for dendrites. From the modelling results in Fig. 3c and f, the maximum local current density, including the effect of kinetics, decreases with increasing peak height at fixed separation and with decreasing peak separation at fixed height (increasing H/S ratio). Therefore, although including the effect of kinetics at the Li/electrolyte interface can explain the constant H/S case, there are still other factors that influence the critical currents for dendrites.
During charging, the deposition of Li builds pressure at the interface because of the viscoplasticity of Li metal.45–47 The pressures at different points across the interface are determined by the local current density distribution (including the effect of interfacial kinetics), which expresses the rate of lithium metal deposition locally, and its consequent creeping flow away from the interface.48 Unlike the planar geometry, the uneven current density distribution on a contoured surface can lead to local pressure accumulation, Fig. 3g, which can reduce the critical current for dendrites below the expected value. Using the current density distribution including the effect of interfacial kinetics, a momentum balance that includes the creep power law for lithium metal49–51 was solved to determine the pressure distribution at the Li/electrolyte interface, see S2 (ESI†) for calculation details. The maximum local excess pressure, i.e., the interfacial pressure minus the stack pressure, was calculated for 1 mA cm−2 geometrical current density and is shown in Fig. 3c and f.
In principle, the mechanical state of the interface and its electrokinetics are coupled. Monroe and Newman showed how interfacial pressure impacts the interfacial resistance at deforming electrochemical interfaces.41 This coupling was considered here in an iterative calculation, in which the mechanical and electrical models were solved simultaneously (S2, ESI†). The iterative calculation (see Fig. S2, ESI†) showed that the kinetic current density was changed by less than 1% when coupled to interfacial pressure, so the interfacial resistance was assumed to remain constant and independent of pressure in further modelling.
As shown in Fig. 3c and f, maximum local pressure increases with increasing peak height at fixed peak separation, and with decreasing peak separation at fixed height (i.e. increasing H/S ratio). Increasing the H/S ratio also increases the interfacial surface area, reducing the average local current density across the interface and as a result reducing the maximum local current density. Although the resultant maximum rate of lithium plating is also lower, the sharper geometry associated with a higher H/S ratio (higher peaks and/or lower peak separation) constrains the creep of the plated lithium metal. Steeper peaks (higher H/S ratio) direct the plated lithium towards the troughs in the solid electrolyte (where the Li protrudes most into the electrolyte), since lithium plating only occurs in the direction normal to the contoured surface. The creeping lithium flow concentrates at and pressurises the bottoms of the troughs, as illustrated in Fig. 3g(ii) and (iii). The opposing effects of lower maximum local current density and higher maximum local pressure with increasing H/S are in accord with the maximum observed in the critical current for dendrites when increasing the H/S ratio, Fig. 3(b) and (e). Any method of increasing the interfacial surface area in an attempt to increase critical current for dendrites will come with inherently limiting mechanical and electrical effects due to the topography of rougher surfaces, which will eventually dominate thus limiting the current density for dendrites.
A recent dendrite propagation model explored the growth of dendrites within the ceramic electrolyte, taking account of surface tension, inhomogeneities and crack dimensions and in particular the correlation between the interfacial pressure and the current density required for a dendrite to grow cracks within a solid electrolyte (ig).37 By invoking this relationship, the effect of the current density and pressure distributions across the contoured surfaces on dendrite growth can be evaluated quantitatively. As shown above, the maximum local current density, including the effect of interfacial kinetics, and maximum interfacial pressure occur at the same location on the contoured surface (tip of the Li protrusions into the solid electrolyte), illustrated in Fig. S3 (ESI†). The magnitude of the local pressure is, of course, dependent on the local current and the creep properties of lithium. When the local current and consequent local pressure are sufficiently high, the crack will lengthen, and this process is associated with a specific geometrical current density. The model is described in S2 (ESI†).
Results are summarised in Fig. 4. The dashed lines in Fig. 4a–c represent the calculated geometrical current densities for dendrite growth, showing how they vary with changes in peak height and peak separation of the contoured surface. The calculated trends follow the experimentally determined values. Comparing the frustums of square pyramids, egg-box and square pyramidal surfaces, the trend in the calculated geometrical current density for dendrite growth agrees with the experimental results, showing the egg-box topography being the best (Fig. 4d). It is important to note that the calculated values in Fig. 4 are just trends and do not reflect the absolute values of the currents required for dendrite growth. Predicting critical currents would require knowledge of the dendritic crack dimensions for each case at the position of the maximum local current and pressure. However, the trends of the calculate and experimental values are in accord.
Footnote |
† Electronic supplementary information (ESI) available. See DOI: https://doi.org/10.1039/d3ee03322h |
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