Does Anisotropic ‘Lattice’ Collapse Always Lead to Cracking in Ni-Rich Layered Oxide Cathode Particles?

Abstract

Single-crystalline Ni-rich layered oxides (LiNi x Mn y Co1−x−y O2; x ≥ 0.8) are promising high-energy-density cathodes for future Li-ion batteries as they can withstand cathode particle cracking, which is a significant contributor to electrochemical capacity loss. The absence of grain/particle boundaries substantially mitigates the build-up of bulk structural strain in these materials generated from the anisotropic structural evolution (i.e., lattice collapse) during electrochemical cycling. However, compared to their polycrystalline counterparts, rigorous evaluations of their long-term electrochemical performance and their dependence on electrode structure changes, impedance, and particle cracking, are still necessary to take it towards commercialisation. Operando X-ray diffraction (XRD) and absorption spectroscopy (XAS) are ideal probes of these bulk electrode structure properties and provide a direct temporal correlation between the battery electrochemistry and the non-equilibrium structural changes in the electrodes. However, such studies often use electrochemically compromised cells modified for X-ray transmission that are neither representative of a real-world full-cell architecture nor operable long-term under industrially relevant cycling conditions, thereby compromising the results' practicality. This is especially problematic for technologically mature cathodes like single-crystalline Ni-rich layered oxides, which require greater scrutiny of their long-term degradation modes after hundreds of cycles. In this work, using in-house operando X-ray studies and large-area post-mortem electron tomography of a (TRL-5) pilot-line-built A7 pouch full cells with industry-relevant specifications, we demonstrate how single-crystalline LiNi0.8Mn0.1Co0.1O2 (NMC811) cathodes can withstand the severe anisotropic structural evolution and show no particle cracking even when cycled under harsh conditions of 2.5–4.4 V at 40 °C for 100 cycles. The bulk structural changes in both electrodes as well as the associated electrochemical performance loss are also evaluated. Furthermore, the validity of the in-house pilot line cell results is benchmarked against a commercially sourced Li-ion cell. In addition to furthering our understanding of single-crystalline Ni-rich cathodes, this work emphasises the need for real-world-relevant reproducible fundamental investigations of academic Li-ion cells and presents a methodology for doing so. Figure 1