Al Surface Research Articles

To elucidate the effect of alloying elements for enhanced nitriding of aluminum: A multiscale computational study

The limitations of aluminum (Al) are discussed in certain industrial applications, owing to its low hardness and wear resistance. To overcome these limitations, surface modification techniques, such as the formation of aluminum nitride (AlN) layers on the Al surface, have been explored. However, conventional surface-nitriding processes have low productivity, and it is essential to develop a cost-effective method to ensure higher nitriding rates. This paper presents the results of a multiscale computational study on the atomic-scale mechanisms involved in gas nitriding processes and the effects of alloying elements on reaction kinetics using density functional theory calculations. This study also provides insights into the thermodynamic stability and kinetics of the process, contributing to the design and optimization of the nitriding process for the formation of AlN on Al surfaces using Thermo-Calc. and microkinetic analyses. This study demonstrates the potential of multiscale computational methods for advancing the understanding of surface modification techniques and their applications for nitriding on the surface of Al and suggests the best alloying element to enhance the nitriding rate.

The effects of Al (111) and Al2O3/Al (111) surfaces on the decomposition of ammonium perchlorate: A DFT-D study

Ammonium perchlorate (AP) is a crucial oxidizing agent in composite solid propellants, where aluminum (Al) is used as an additive to increase the energy density of composite solid propellants. The interaction between AP and Al significantly improves the ignition and combustion performance of propellants, but the mechanism of their interactions still lacks essential understanding, especially the interaction between AP and Al, as well as the Al surface containing aluminum oxide (Al2O3). To solve this problem, the adsorption and decomposition processes of AP and its decomposition products such as perchloric acid (HClO4) and ammonia (NH3) on the pure-Al (111) and Al2O3/Al (111) surfaces were studied by using the density functional theory (DFT). The effects of temperature and pressure on the adsorption and reactions were discussed. AP tends to adsorb on the pure-Al (111) surface with O-termination, while under the influence of Al2O3, AP is more inclined to adsorb on the surface of Al2O3/Al (111). At the low-temperature stage, the Al2O3 molecules on the surface of Al (111) promote the disengagement H of AP decomposition and the adsorption and decomposition of NH3, while at the high-temperature stage, the pure Al surface is more conducive to the AP disengagement H and NH3 decomposition. The increase in the pressure is in favor of NH3 adsorption, but the effect gradually decreases. HClO4 cannot adsorb on the pure-Al (111) and AP (001) surfaces, but it can adsorb on the surface of Al2O3/Al (111). In the gas phase, the decomposition of HClO4 priors to NH3. At the high temperature and pressure, the pure-Al (111) surface can contribute significantly to the adsorption and activation of NH3. The findings are very valuable for regulating the combustion of solid propellants.

Revisiting a Cu-rich layer on the aluminum surface after twin-jet electropolishing

Twin-jet electropolishing (TJE) is a well-known method to prepare Cu-containing Al alloys for transmission electron microscopy (TEM) observation. Previous studies have reported a Cu-rich layer usually formed between Al matrix and outermost alumina layer at the electropolished Al surface. However, characteristics and formation mechanisms of the Cu-rich layer remain largely unexplored. Herein, configurations, formation process and property of the Cu-rich layer formed during TJE of Al alloys are revealed detailly employing aberration-corrected scanning TEM (STEM), STEM image simulations and first-principles calculations. The results reveal a new orientation relationship between the Cu-rich layer (θ’-Al2Cu) and Al matrix, which produces a low interfacial Al strain field. Formations of ∼2-nm-thick θ’ layer and its beneath ∼6-nm-thick Cu diffusion zone at the electropolished Cu-containing Al surface are mainly associated with traces of Cu in the electrolyte and anodization. Selective oxidation of elements, Cu-emitting alumina layer and spontaneous solute Cu segregation at the Al surface are also responsible for formations of the θ’ layer and Cu diffusion zone. Further study reveals that the θ’ layer behaves a strong self-healing ability after damaged by high-energy electron beam. The obtained results provide a potential insight into the surface modification of metals and alloys using electrochemical method.

Hybrid Organic-Inorganic Additive for Robust Al Anode in Alkaline Aluminum-Air Battery.

Aluminum-air batteries (AABs), known for their high energy density, environmental friendliness, and cost-effectiveness, show immense promise in the realm of energy conversion applications. Nonetheless, their commercialization has encountered inherent challenges of Al anode corrosion and material degradation. In this study, economical hybrid electrolyte additives to inhibit the Al corrosion are developed, safeguarding the integrity of the Al anode. Due to the synergistic interplay between the organic compound dithiothreitol, and inorganic compounds zinc chloride, a robust zinc film is formed on the Al surface This Zn film plays a pivotal role in quelling parasitic hydrogen evolution reactions that typically can plague the Al electrode. Consequently, the as-prepared hybrid additive culminates in a remarkable enhancement to AABs, delivering exceptional discharge capacity of 1793.37mAhg-1 , high energy density of 2047Whkg-1 , and excellent battery longevity (over 20h in on/off cycling tests). This study, therefore, introduces a novel approach in utilizing hybrid electrolyte additives to effectively counteract corrosion-related challenges and boost the stability and performance of AABs.

Development of trimetallic cobalt-nickel-vanadium oxide anticorrosion coatings for the protection of AA2024 Al alloy specimens against sodium chloride solutions

Trimetallic cobalt-nickel-vanadium oxide (CoNiVOx) thin films were fabricated on aerospace grade AA2024 Al alloy specimens to investigate their behavior as anticorrosion coatings in a sodium chloride (NaCl) medium. Compact and homogenous nanostructured CoNiVOx coatings were developed using aerosol-assisted chemical vapor deposition by varying the deposition duration from 45 to 150 min at a constant temperature (475 °C). The structure and composition of the trimetallic CoNiVOx thin films were comprehensively investigated using X-ray diffraction, transmission electron microscopy, scanning electron microscopy/energy dispersive X-ray spectroscopy, and X-ray photoelectron spectroscopy, which demonstrated the successful synthesis of CoO/NiO/VO composite materials. The electrochemical corrosion properties of the trimetallic CoNiVOx films in a 3.5 % NaCl solution were determined using Tafel extrapolation and impedance spectroscopic tests, whereas the electrochemical stability and localized corrosion characteristics were determined using scanning electrochemical microscopic analyses. This study demonstrates that the trimetallic CoNiVOx oxide layer fabricated for 150 min exhibited an effective barrier protection performance on Al surfaces against corrosive attack in NaCl media.

Modification of Al Surface via Acidic Treatment and its Impact on Plating and Stripping.

Amorphous Al2 O3 film that naturally exists on any Al substrate is a critical bottleneck for the cyclic performance of metallic Al in rechargeable Al batteries. The so-called electron/ion insulator Al oxide slows down the anode's activation and hinders Al plating/stripping. The Al2 O3 film induces different surface properties (roughness and microstructure) on the metal. Al foils present two optically different sides (shiny and non-shiny), but their surface properties and influence on plating and stripping have not been studied so far. Compared to the shiny side, the non-shiny one has a higher (~28 %) surface roughness, and its greater concentration of active sites (for Al plating and stripping) yields higher current densities. Immersion pretreatments in Ionic-Liquid/AlCl3 -based electrolyte with various durations modify the surface properties of each side, forming an electrode-electrolyte interphase layer rich in Al, Cl, and N. The created interphase layer provides more tunneling paths for better Al diffusion upon plating and stripping. After 500 cycles, dendritic Al deposition, generated active sites, and the continuous removal of the Al metal and oxide cause accelerated local corrosion and electrode pulverization. We highlight the mechanical surface properties of cycled Al foil, considering the role of immersion pretreatment and the differences between the two sides.

Microwave plasma-produced Al/Al2O3 microparticles as precursors for high-temperature high-strength composites

Microwave plasma-produced Al/Al2O3 microparticles as precursors for high-temperature high-strength composites

In Situ Monitoring of the Al(110)‐[EMImCl] : AlCl3 Interface by Reflection Anisotropy Spectroscopy

AbstractRecently, Al‐batteries (AlBs) have become promising candidates for post‐lithium batteries, with [EMImCl] : AlCl3 (1 : 1.5) as the most commonly used electrolyte. However, progress in the development of AlBs is currently hindered by the lack of understanding of its solid‐electrolyte interface. Monitoring the structure of this interface under operational conditions by complementary spectroscopy could help to identify and overcome bottlenecks of the system. Reflection anisotropy spectroscopy (RAS), an optical in situ technique, provides access to physical and chemical properties of electrochemical interfaces on an atomistic level. Herein, we report the first example of RAS as an in situ characterization technique for non‐aqueous battery systems, investigating an Al(110)‐based model system. During chemical pre‐treatment in [EMImCl] : AlCl3, the Al(110) surface passivation film is modified. The oxide film is partially etched while an inhomogeneous passivation layer forms, increasing the surface roughness. Upon electrochemical cycling, applied potential‐dependent oscillations of the anisotropy are observed and demonstrate the applicability of RAS to monitor phenomena such as plating/stripping and surface passivation in real‐time.

DFT , Monte Carlo and Molecular Dynamics modeling of the Carvacrol, Camphor and Linalool /Al(111) Interaction

In this work, the interaction of three natural compounds: carvacrol (Inh-1), camphor (Inh-2), and linalool (Inh-3) on the Al(111) surface have been studied using DFT/B3LYP/6-31G(d,p), to understand adsorption behavior on the metal surface. The results obtained show a strong correlation between the inhibitory efficiency (IE%) of aluminum corrosion and the quantum chemical parameters of reactivity derived from DFT. In addition, the interactions between the three natural inhibitors and the aluminum surface were studied using Monte Carlo (MC) and molecular dynamics simulations, as a result, the three molecules have strong interactions with the metal surface and thus have excellent predictive power for inhibition against metal corrosion, the three corrosion inhibitors have higher inhibitory efficiency and can be used as inhibitors to minimize the corrosion rate of the metal, therefore, the efficiency of Inh-1 is more important than the efficiency of Inh-2 and Inh-3.

Interactions and mechanisms of sulfonium salts with metal interfaces: An in-depth computational exploration of COSMO-RS profiles, quantum chemistry and molecular dynamics on iron, copper, and aluminum

Sulfonium salts (SSs) exhibit diverse structural and electronic attributes, offering rich prospects in corrosion inhibition strategies. This research employed a combination of methodologies, such as COSMO-RS and Density Functional Theory (DFT), to investigate six specific SSs, including Phenacyl dimethyl sulfonium bromide (SH) and its p-derivatives 4-Methyl-SH (SM), 4-Chloro-SH (SC), 4-Bromo-SH (SB), 4-Methoxy-SH (SMe), and 4-Nitro-SH (SN). Additionally, Molecular Dynamics (MD) simulations were utilized to examine their adsorption configurations and affinities to Fe, Cu, and Al surfaces. The initial investigation through COSMO-RS sigma-profiles confirmed the SSs' propensity for hydrogen bonding in water. Quantum chemical calculations (QCCs) further elucidated the distinctive reactivity effects of various functional groups. For instance, methyl-substituted SS displayed remarkable reactivity with metals, whereas nitro groups led to strong electron acceptance in the SN molecule. Fukui functions identified pronounced electrophilic and nucleophilic characteristics within atoms, with carbonyl atoms emerging as key reactive sites. MD simulations provided insights into the adsorption of SSs on metal surfaces, revealing parallel disposition as the most stable mode and a strong affinity towards copper, iron, and aluminum, in the order of SM > SMe > SH > SB > SC > SN. This correlation aligned with the ΔN data. The study revealed the substantial effects of both methyl and methoxy groups on SSs' reactivity with metals, with electron-withdrawing groups exerting a negative influence. Overall, the findings enrich our comprehension of SSs and offer a solid foundation for their further exploration and utilization, especially in customized design and applications such as corrosion protection.

Effects of the Second Anodization Parameters on the Hydrophobicity and Anti-Icing Properties of Al Surface with Composite Nanopore Structure

Icing on transmission lines often causes potential electric damage in power systems. Superhydrophobic anodized Al conductors have been proposed to have good anti-icing properties. In this study, superhydrophobic anodized Al conductors with composite nanopore structures were prepared by a two-step anodization. The microstructure, hydrophobicity, and anti-icing properties of composite nanopore structures were compared and studied. The optimal preparation parameter was determined as a current density of 0.04375 A/cm2 and anodization time of 15 min. Compared with the bare substrate, the optimal anodized Al surface of the composite nanopore structures show excellent hydrophobic and anti-icing properties, including a contact angle of 173°, a contact angle hysteresis of 0.122°, an ice adhesion strength of 0.71 kPa, and a glaze icing weight of 0.1 g after the 8 h. Therefore, the prepared anodized Al surface of composite nanopore structures with good anti-icing properties has profound application potential for overhead transmission lines.

Elucidating Interfacial Dynamics of Ti-Al Systems Using Molecular Dynamics Simulation and Markov State Modeling.

Due to their remarkable mechanical and chemical properties, Ti-Al-based materials are attracting considerable interest in numerous fields of engineering, such as automotive, aerospace, and defense. With their low density, high strength, and resistance to corrosion and oxidation, these intermetallic alloys and metal-compound composites have found diverse applications. However, additive manufacturing and heat treatment of Ti-Al alloys frequently lead to brittleness and severe formation of defects. The present study delves into the interfacial dynamics of these Ti-Al systems, particularly focusing on the behavior of Ti and Al atoms in the presence of TiAl3 grain boundaries under experimental heat treatment conditions. Using a combination of molecular dynamics and Markov state modeling, we scrutinize the kinetic processes involved in the formation of TiAl3. The molecular dynamics simulation indicates that at the early stage of heat treatment, the predominating process is the diffusion of Al atoms toward the Ti surface through the TiAl3 grain boundaries. Markov state modeling identifies three distinct dynamic states of Al atoms within the Ti/Al mixture that forms during the process, each exhibiting a unique spatial distribution. Using transition time scales as a qualitative measure of the rapidness of the dynamics, it is observed that the Al dynamics is significantly less rapid near the Ti surface compared to the Al surface. Put together, the results offer a comprehensive understanding of the interfacial dynamics and reveal a three-stage diffusion mechanism. The process initiates with the premelting of Al, proceeds with the prevalent diffusion of Al atoms toward the Ti surface, and eventually ceases as the Ti concentration within the mixture progressively increases. The insights gained from this study could contribute significantly to the control and optimization of manufacturing processes for these high-performing Ti-Al-based materials.

Hybrid Ceramic Self-Healing Coatings for Corrosion Protection of Al Alloys in 3% NaCl Solution

This work focuses on the development of sol–gel self-healing coatings for corrosion protection of Al alloys. The use of this method will help to reduce the costs associated with the coating as well as their environmental impact. Coatings were made of a titania matrix loaded with microparticles of poly(vinyl-alcohol) (PVA) containing cerium nitrate as an inhibitor. The PVA particles dissolve in water, so that the cerium nitrate deposits on the Al surface subjected to corrosion. The PVA microspheres were made via the emulsion method, and then loaded with cerium nitrate. The amount of cerium nitrate loaded in the microspheres was evaluated using UV–Vis. As a second step, the titania coating with embedded PVA microspheres loaded with cerium nitrate was deposited on an AA6082 substrate via a sol–gel route. The corrosion resistance of the coated samples was tested in NaCl solution. The coating microstructure, before and after the corrosion tests, was analysed with the use of an SEM (scanning electron microscope) and EDS (energy dispersive spectroscopy), while the corrosion resistance was investigated by EIS (electrochemical impedance spectroscopy). The results showed that the coatings were uniform and compact. They also showed the ability of the hybrid TiO2-based coating to provide protection for the AA6082 from corrosion. The coatings with an induced defect (scratch) were also analysed, and the EIS analysis of the coatings over time showed an increase in resistance, confirming the ability of the coating to heal itself.

Corrosion resistance and stability of superhydrophobic surfaces with hierarchical micro/nanostructures induced by nanosecond and femtosecond lasers

A innovative approach is introduced to enhance the corrosion resistance and stability of the aluminum (Al) substrates. This method involves the integration of nanosecond and femtosecond lasers (ns-fs-lasers) processing with the silanization treatment procedure. Ns-fs-lasers are employed to generate distinct hierarchical periodic micro/nanostructures, resulting in heightened roughness and micro/nanostructures on the Al surfaces in comparison to single laser texturing. Furthermore, the silanization processes effectively lower the surface free energy of the laser-induced samples. In this study, water contact angles (WCA) and roll angles (RA), as well as electrochemical impedance spectra (EIS) and potentiodynamic polarization (PDP) outcomes, reveal that the surfaces induced by ns-fs-lasers exhibit superior superhydrophobicity, corrosion resistance, and corrosion stability compared to surfaces induced by ns-laser alone. Consequently, the combination of ns-fs-lasers induced surfaces and the silanization process presents a promising avenue for augmenting the corrosion resistance and stability of superhydrophobic Al surfaces.

An inorganic-organic protective anode interface towards high‐performance Al-air battery

Aqueous aluminium-air batteries (AABs) are promising candidates for next-generation energy storage devices owing to their high theoretical voltage and theoretical capacity of 2.98 Ah g−1 with additional advantages of aluminium (Al) being abundant, cost-effective, and recyclable. Despite striking advantages, practical application of Al-air batteries is hindered by undesirable self-corrosion and passivation of Al surface, as well as severe hydrogen evolution reaction (HER), thereby reducing anodic efficiency and battery capacity. To address these issues, herein, a dual protective coating comprising LDH-PVA-acetal as an inorganic-organic hybrid material has been developed. This coating forms a stable film over the Al substrate and synergistically suppresses self-corrosion and HER by blocking bulk water molecules from direct contact with the Al anode along with slow diffused release of hydroxide ions. The battery assembled utilizing LDH-PVA-acetal/Al as anode demonstrates an outstanding capacity of 2577 mAh g−1 and 2698 mAh g−1 with 86.4% and 90.5% anodic utilization @30 mA cm−2 and 50 mA cm−2. A waste beverage can coated with LDH-PVA-acetal showed practical applicability towards waste to wealth, thus, demonstrating potential application towards corrosion inhibition in alkaline media for other metals as well.

Atomic-Level Description of Chemical, Topological, and Surface Morphology Aspects of Oxide Film Grown on Polycrystalline Aluminum during Thermal Oxidation—Reactive Molecular Dynamics Simulations

Oxidation results in the formation of an oxide film whose properties and structure can be tailored by controlling the oxidation conditions. Reactive molecular dynamics simulations were performed to study thermal oxidation of polycrystalline Al substrates as a function of O2 density and temperature. The structural, chemical, and topological aspects of polycrystalline Al (poly-Al) substrates and oxide films formed upon oxidation were studied. The studies were supported by surface topography and morphology analyses before and after oxidation. An analysis of Al–O atomic pair distribution showed the development of long-range order in the oxide films grown upon exposure to low-density (0.005 g/cm3) and high-density (0.05 g/cm3) O2 gas. The long-range order was more apparent for the high-density environment, as the oxide films formed in low-density O2 gas did not fully cover the poly-Al surface. The dominance of over-coordinated polyhedral units in a tightly packed structure was indicative of medium- and long-range atomic order in the oxide films. The two-phase structure of the oxide was found in the films, with a crystalline phase at the metal/oxide interface and an amorphous phase at the oxide/O2 interface. The combination with topological analyses supported the conclusions of the chemical analysis and enabled us to capture an amorphous-to-crystalline phase transformation in the oxide films with increasing oxygen density and temperature. An important effect of Al surface roughness before oxidation on the behavior of the metal/oxide interface and on the oxide film structure was observed.

Surface-Induced Electronic and Vibrational Level Shifting of [Fe(py)2bpym(NCS)2] on Al(100).

It is essential that one understands how the surface degrees of freedom influence molecular spin switching to successfully integrate spin crossover (SCO) molecules into devices. This study uses density functional theory calculations to investigate how spin state energetics and molecular vibrations change in a Fe(II) SCO compound named [Fe(py)2bpym(NCS)2] when deposited on an Al(100) surface. The calculations consider an environment-dependent U to assess the local Coulomb correlation of 3d electrons. The results show that the adsorption configurations heavily affect the spin state splitting, which increases by 10-40 kJmol-1 on the surface, and this is detrimental to spin conversion. This effect is due to the surface binding energy variation across the spin transition. The preference for the low-spin state originates partly from the strong correlation effect. Furthermore, the surface environment constrains the vibrational entropy difference, which decreases by 8-17 Jmol-1K-1 (at 300 K) and leads to higher critical temperatures. These results suggest that the electronic energy splitting and vibrational level shifting are suitable features for characterizing the spin transition process on surfaces, and they can provide access to high-throughput screening of spin crossover devices.

Atomic pins bridging integrated surface to assist high-rate stability for Co-free Li-rich cathode

Li- and Mn-rich oxides (LMR) have emerged as promising cathode materials for next-generation Li-ion batteries due to their cost effectiveness, impressive capacity, and high energy density. However, the poor electrochemical kinetics and structural instability in hostile interface environments have result in continuous voltage/capacity decay and undesirable rate performance, impeding the large-scale commercial application of LMR materials. In this study, we introduce an atomic pins-assisted integrated surface reconstruction (AISR) strategy to address the interfacial degradation and instability issues. Utilizing the bidirectional diffusion effect of the aluminum-containing intermediate layer during the heat treatment process, we employ aluminum atoms as bridging centers to in situ construct a composite interface structure. This approach capitalizes on the element diffusion reaction and anchoring effect to achieve multifunctional modification through the Al-based ionic conductor network constructing and near-surface Al doping for LMR material. Intriguingly multiple kinetic investigations and calculations reveal that the epitaxial ionic conductor layer suppresses interfacial side reactions, enhances ionic conductivity, and improves electronic conductivity by regulating cationic/anionic redox activity through Al surface doping.Impressively, the modified electrodes exhibited an increased reversible capacity at both 0.1C/5C rates (0.1C, 2 ∼ 4.8 V, from 264.2 mAh∙g−1 to 274 mAh∙g−1; 5C, 2 ∼ 4.6 V, from 145.5 mAh∙g−1 to 197.9 mAh∙g−1) and improved capacity retention after 250 cycles at 1C/5C rates (2 ∼ 4.6 V: 1C, from 69.46% to 81.92%; 5C from 57.73% to 81.35%). We systematically summarized the rate-dependent failure mechanism and the corresponding integrated interface reconstruction principle. These key findings offer valuable insights for the development of high-energy–density and long-life lithium-ion batteries in commercial applications.

Methyl-Functionalized Al-Based MOF ZJU-620(Al): A Potential Physisorbent for Carbon Dioxide Capture.

Developing Al-based metal-organic frameworks (MOFs) with moisture-resistance ability is a challenge for carbon dioxide (CO2) capture. Methyl-functionalized Al-based MOF ZJU-620(Al), with excellent chemical-thermal stability and specific surface area of 1347 m2/g, observed here, is a potential adsorbent for CO2 capture with good recyclability and large capacity up to 4.25 mmol/g at 298 K and 1 atm. CO2 molecules are largely trapped on two types of sites. One (site I) is near the AlO6 clusters, and another (site II) is between two parallel benzene rings with a distance of 6.64 Å. ZJU-620(Al) can be used for CO2/N2 (15/85) separation with the excellent selectivity up to 107.20 at 273 K and 31.93 at 298 K, and the separation factor of 13.68. It is also with excellent moisture-resistance ability due to 5% breakthrough time (outlet concentration reached the 5% of inlet concentration) without reduction at 80% relative humidity than under dry conditions. Water molecules occupy a small amount of CO2 adsorption site I, but they almost do not occupy the CO2 adsorption site II due to hydrophobic methyl-functional ligands. Moreover, CO2 can be adsorbed on the ZJU-620(Al) surface through C═O···H binding of water molecules with high affinity. Thus, ZJU-620(Al) is a candidate adsorbent for CO2 capture and separation especially under humidity conditions.

Proof of Concept: The GREENcell—A Lithium Cell with a F-, Ni- and Co-Free Cathode and Stabilized In-Situ LiAl Alloy Anode

Given the rising upscaling trend in lithium-ion battery (LiB) production, there is a growing emphasis on the environmental and economic impacts alongside the high energy density demands. The cost and environmental impact of battery production primarily arise from the critical elements Ni, Co, and F. This drives the exploration of Ni-free and Co-free cathode alternatives such as LiMn2O4 (LMO) and LiFePO4 (LFP). However, the absence of Ni and Co results in reduced capacity and insufficient cyclic stability, particularly in the case of LMO due to Mn dissolution. To compensate for both low cathode capacitance and low cycle stability, we propose the GREENcell, a lithium cell combining a F-free polyisobutene (PIB) binder-based LMO cathode with a stabilized in -situ LiAL alloy anode. A LiAl alloy anode with the chemical composition of LiAl already shows a theoretical capacity of 993 Ah·kg−1. Therefore, it promises extraordinarily higher energy densities compared to a commercial graphite anode with a capacity of 372 Ah·kg−1. Following an iterative development process, different optimization strategies, especially those targeting the stability of the Al-based anode, were evaluated. During Al foil selection, foil purity and thickness could be identified as two of the dominant influencing parameters. A pressed-in stainless steel mesh provides both mechanical stability to the anode and facilitates alloy formation by breaking up the Al oxide layer beforehand. Additionally, a binder-stabilized Al oxide or silicate layer is pre-coated on the Al surface, posing as a SEI-precursor and ensuring a uniform liquid electrolyte distribution at the phase boundary. Employing a commercially available Si-containing Al alloy mitigated the mechanical degradation of the anode, yielding a favorable impact on long-term stability. The applicability of the novel optimized GREENcell is demonstrated using laboratory coin cells with LMO and LFP as the cathode. As a result, the functionality of the GREENcell was demonstrated for the first time, and thanks to the anode stabilization strategies, a capacity retention of >70% after 200 was achieved, representing an increase of 32.6% compared to the initial Al foil.