Durability Of Batteries Research Articles

Innovative approaches to optimizing Li-Ion battery cooling performance using gas mixtures

This study investigates the critical issue of thermal management in lithium-ion batteries, a vital concern for enhancing battery performance, safety, and longevity. While more complex cooling systems like liquid cooling, phase change materials, and two-phase systems offer superior thermal performance due to their higher heat transfer capabilities, they come with significant drawbacks. These include increased system complexity, higher costs, added weight, and the potential for leaks or other failures that can compromise safety and reliability. Consequently, simpler air-based cooling systems are often preferred in many applications, despite their inherently lower h coefficient. To bridge the performance gap between air and liquid cooling without resorting to complex engineering solutions, this study focuses on enhancing the h coefficient of air-based systems using innovative refrigerant gas mixtures. The use of refrigerant gas mixtures, specifically a blend of R1234ze(E), nitrogen, and neon, as an alternative to traditional cooling methods was explored. The study employed a comprehensive FEM model and experimental validation to evaluate free and forced convection in a slender, vertical cylindrical configuration. To analyze the impact on convective heat transfer, the key parameters CRate, T0 and Tamb were systematically varied. A dimensionless analysis then evaluated how thermodynamic properties influence h coefficient. This analysis led to the derivation of a dimensionless heat transfer function h(ρ, Cp, k, μ). The study aimed to significantly improve the efficiency of h by optimizing the gas mixture properties. The “Mixture Study” identifies the optimal refrigerant composition, where a specific mixture α of 86 % R1234ze(E), and 14 % neon demonstrated the best balance between heat transfer efficiency and enhanced thermal capacity. The heat transfer coefficient increases by around 65 % during natural convection and by around 80 % during forced convection. The percentage reduction of the thermal difference in temperature reaches approximately 10 % with a maximum of 4 K in natural convection conditions and a maximum of 36.5 % and a reduction of approximately 10 K compared to air cooling alone, effectively maintaining the battery within the optimal operating range of 293.15 K to 333.15 K. Notably, this composition increased the thermal power absorbed by the mixture by over 100 % under the same thermal difference. This research therefore provides valuable insights for developing more effective gas cooling strategies that ultimately enhance the performance, safety, and durability of batteries in various applications. By integrating the benefits of both cooling methods, the study paves the way for innovative thermal management solutions in battery technology.

Predictive analytics for prolonging lithium-ion battery lifespan through informed storage conditions

The capacity degradation of lithium-ion batteries occurs both during storage and operational usage. This paper investigates the capacity degradation of lithium-ion batteries during storage (calendar ageing) by analysing the interplay of storage temperature, state-of-charge (SOC), and time. Leveraging the machine learning techniques of Gaussian process regression and extreme gradient boosting (XGBoost), a predictive model is developed to characterize the degradation patterns. The study includes a sensitivity analysis of stress factors to identify their relative impact on degradation. The insights gained from this analysis are utilized to recommend optimal storage conditions, offering practical guidance for enhancing the durability and performance of lithium-ion batteries in real-world applications.

State-of-health estimation for lithium-ion batteries based on Kullback–Leibler divergence and a retentive network

Accurate state-of-health (SOH) estimation is crucial for the lithium-ion battery industry, as it underpins the safety, durability, and reliability of lithium-ion batteries. Currently, most researchers use various methods of health indicator (HI) extraction for the SOH estimation of batteries. However, these methods may require certain expertise and prior knowledge to achieve accurate modeling, being affected by measurement noise and other factors. To solve the abovementioned problems, three Kullback–Leibler (KL) divergence features based on partial voltage sequences are proposed as new HIs that are independent of prior knowledge and strongly correlated with SOH. Moreover, a modified retentive network is proposed to enhance SOH estimation accuracy and better utilize HIs than traditional deep learning methods, which have high training costs and insufficient accuracy. To ensure consistent extraction of KL divergence features across various experimental conditions and time intervals, a B-spline algorithm is utilized for interpolation. The effectiveness of the proposed method is validated through analysis of Pearson correlation coefficients and experiments conducted in four dimensions. Additionally, the potential of using the proposed method to compress data on the cloud-side is explored.

Electrochemical and aging model of li-ion batteries and estimation of total number of cycles during the lifecycle of the battery

Fast charging is a critical factor for the widespread adoption of electric vehicles (EVs), yet it poses challenges to the durability of lithium-ion batteries (LiBs). This study develops an aging model for a 10 Ah LiB cell using COMSOL Multiphysics, integrating a one-dimensional electrochemical model with a zero-dimensional thermal model. The model is constructed using cell design and electrochemical parameters derived from existing literature, tailored to the specific electrode and electrolyte materials utilized in this study. Key aging phenomena, such as the Solid Electrolyte Interface (SEI) growth and lithium plating, are embedded within the model to simulate the aging patterns and the interplay between these factors across various C-rates and temperatures. Simulation results suggest that while higher charging rates can reduce charging time, they also lead to increased degradation, with lithium plating becoming more severe at these elevated rates. The model also indicates that temperature management during cell operation can influence cycle life, with strategic temperature increases potentially mitigating some negative effects of fast charging. The study also explores the concept of total charging time as an alternative metric for battery wear, examining its relationship with the charging current profile and temperature. Results indicate that while fast charging offers convenience, it significantly impacts cycle life, underscoring the need for optimized charging strategies. The insights from this work enhance the understanding of Li-ion cell aging mechanisms, shedding light on the complex trade-offs between charging speed, temperature management, and lifespan. This contributes to the development of more sophisticated battery management systems and charging protocols that aim to extend the operational life of LiBs while accommodating the demands of fast charging.

Molecule Design for Non-Aqueous Wide-Temperature Electrolytes via the Intelligentized Screening Method.

Operating a lithium-ion battery (LIB) in a wide temperature range is essential for ensuring a stable electricity supply amidst fluctuating temperatures caused by climate or terrain changes. Electrolyte plays a pivotal role in determining the temperature durability of batteries. However, specialized electrolytes designed for either low or high temperatures typically possess distinct features. Therefore, wide-temperature electrolytes (WTEs) are necessary as they encompass a combination of diverse properties, which complicates the clear instruction of WTE design. Here we represent an artificial intelligence (Al)-assisted workflow of WTE design through stepwise parameterizations and calculations. Linear mono-nitriles are identified as ideal wide-liquidus-range solvents that can "softly" solvate lithium ions by weak interactions. In addition, the explainable modules revealed the halogenoid similarity of cyanide as fluorine on the electrolyte properties (e.g. boiling point and dielectric constant). With the further introduction of an ether bond, 3-methoxypropionitrile (MPN) has been eventually determined as a main electrolyte solvent, enabling the battery operation from -60 to 120 °C. Particularly, a LiCoO2/Li cell using the proposed WTE can realize stable cycling with capacity retention reaching 72.3 % after 50 cycles under a high temperature of 100 °C.

Molecule Design for Non‐Aqueous Wide‐Temperature Electrolytes via the Intelligentized Screening Method

AbstractOperating a lithium‐ion battery (LIB) in a wide temperature range is essential for ensuring a stable electricity supply amidst fluctuating temperatures caused by climate or terrain changes. Electrolyte plays a pivotal role in determining the temperature durability of batteries. However, specialized electrolytes designed for either low or high temperatures typically possess distinct features. Therefore, wide‐temperature electrolytes (WTEs) are necessary as they encompass a combination of diverse properties, which complicates the clear instruction of WTE design. Here we represent an artificial intelligence (Al)‐assisted workflow of WTE design through stepwise parameterizations and calculations. Linear mono‐nitriles are identified as ideal wide‐liquidus‐range solvents that can “softly” solvate lithium ions by weak interactions. In addition, the explainable modules revealed the halogenoid similarity of cyanide as fluorine on the electrolyte properties (e.g. boiling point and dielectric constant). With the further introduction of an ether bond, 3‐methoxypropionitrile (MPN) has been eventually determined as a main electrolyte solvent, enabling the battery operation from −60 to 120 °C. Particularly, a LiCoO2/Li cell using the proposed WTE can realize stable cycling with capacity retention reaching 72.3 % after 50 cycles under a high temperature of 100 °C.

Current Collector Primers with Improved Physical and Electrochemical Properties

Lithium-ion batteries are the dominant technology for powering the growing markets of electric vehicles, consumer electronics, and grid storage. However, to meet the increasing demands for higher energy density, faster charging, lower cost, and longer cycle life, continued research of new materials and designs are required. One of the key components that affects the performance and durability of lithium-ion batteries is the current collector, which provides a conductive substrate for active materials. The interfacial conductivity, adhesion, and corrosion resistance of these foils is largely dictated by their native oxide surface layer. To improve any of these features, specialized primers may be applied prior to electrode manufacturing, presenting a unique electrode/active material interface. For instance, carbon-coatings may be applied to aluminum to improve the conductivity and adhesion of lithium iron phosphate (LFP) formulations. These carbon coatings are limited in their cost, thickness, and performance, particularly in next generation cell designs and application methods. PPG is exploring novel current collector coating technologies addressing the physical, electrochemical, and stability requirements of these chemistries and manufacturing process. In this presentation, we will elaborate on coatings development and the effect that novel primer layers have on mechanical properties and single-layer pouch cell cycle life.

(Battery Division Postdoctoral Associate Research Award Sponsored by MTI Corporation and the Jiang Family Foundation) Science of Multiphysics Behavior of Si/C Composite Anodes in High-Energy-Density Lithium-Ion Batteries

The rapidly growing demands on energy storage technologies over the last decade have imposed further requirements for the high energy/power density, safety, and durability of lithium-ion batteries (LIBs). Si/C composite materials have attracted enormous research interest as the most promising candidates for the anodes of next-generation lithium-ion batteries, owing to their high energy density and mechanical buffering property. However, the major disadvantage of materials with ultra-high capacities, such as Si-based materials, is the significant volume change during cycling, which further leads to mechanical and electrochemical degradation. However, a sophisticated and quantitative understanding of the highly electrochemical-mechanical coupling behaviors is still lacking.A comprehensive computational model is indispensable in the developing process of the excellent performance of anode material due to the low-realizability, inconvenience, and high-cost of experiments, which also provides powerful tools for fabrication guidance of novel Si/C composites designs. Hence, a multiphysics modeling framework is established with a detailed geometric description to quantitatively reveal the underlying governing mechanisms of Si/C composite anode behaviors. We studied the effects of the Si weight percentage, the Si-related particle distribution, the Si-related particle size, the mechanical constraint, and the binder domain gradient on the battery performance regarding the potential behavior, capacity delivery, mechanical stress/strain, Li plating, and polarization evolution. In our study, we used silicon monoxide (SiO) as the Si element source and graphite (Gr) as the C element source. Results discover that an 8-10 wt% of SiO would be an optimal choice regarding capacity delivery and minimizing Li plating under 1C constant current charging condition. Positioning SiO particles near the separator and reducing the sizes of SiO particles are also demonstrated to be beneficial for electrochemical performance with trivial influence on mechanical mismatch. In addition, the mechanical constraint demonstrates a balanced effect on the overall performance of cells and the local behaviors of particles. Our findings also indicate that reducing the proportion of carbon-binder domain (CBD) in the upper domain (near the anode surface) compared to the lower domain (near the current collector) positively influences electrochemical performance, particularly in terms of capacity and Li plating. However, such an arrangement introduces potential risks of mechanical failures and we recommend to incorporate a higher proportion of CBD alongside the SiO particles. Finally, an anode design with a lower CBD proportion in the upper domain exhibits superior rate performance.This study explores the multiphysics behavior of Si/C anodes material using a comprehensive methodology combining experimental and FEA techniques, systematically revealing the coupling mechanism among various physical fields, as well as providing efficient and powerful tools in the design, development, and evaluation of high energy density lithium-ion batteries.

An energy management strategy for fuel cell hybrid electric vehicle based on HHO-BiLSTM-TCN-self attention speed prediction

This research aims to improve the performance and economics of fuel cell hybrid electric vehicles (FCHEVs), validated and established by introducing an innovative energy management strategy (EMS) based on a speed-predictive fusion model. Firstly, a mixed prediction model was built based on BiLSTM, TCN, and Self-attention (SA) mechanism to accurately search, capture and fuse multi-granularity features in time series. Then, Harris-Hawk Optimization (HHO) was used to optimize the dropout rate and model learning rate of the combined BiLSTM-TCN-SA time series model to improve the prediction accuracy and generalization ability of the model. Finally, stochastic model predictive control was combined with BiLSTM-TCN-SA to form SMPC-NSGA III algorithm, which was used for multi-objective optimization of fuel economy, fuel cell durability and battery durability. In this study, the effectiveness of the proposed strategy was verified under the condition of CLTC-P driving cycle. The experimental results showed that RMSE and R2 of HHO-BiLSTM-TCN-SA velocity prediction model are 1.169 and 0.998, respectively. In addition, the output of the model is within the confidence interval of 97.5 % of the real speed, and there is no significant difference, which is statistically significant. Under the SMPC-NSGA III strategy, the average efficiency of the fuel cell was increased by 12 % and 1 % respectively.

Influence of Vinylene Carbonate and Fluoroethylene Carbonate on Open Circuit and Floating SoC Calendar Aging of Lithium-Ion Batteries

The purpose of this study was to investigate the calendar aging of lithium-ion batteries by using both open circuit and floating current measurements. Existing degradation studies usually focus on commercial cells. The initial electrolyte composition and formation protocol for these cells is often unknown. This study investigates the role of electrolyte additives, specifically, vinylene carbonate (VC) and fluoroethylene carbonate (FEC), in the aging process of lithium-ion batteries. The results showed that self-discharge plays a significant role in determining the severity of aging for cells without additives. Interestingly, the aging was less severe for the cells without additives as they deviated more from their original storage state of charge. It was also observed that the addition of VC and FEC had an effect on the formation and stability of the solid electrolyte interphase (SEI) layer on the surface of the carbonaceous anode. By gaining a better understanding of the aging processes and the effects of different electrolyte additives, we can improve the safety and durability of lithium-ion batteries, which is critical for their widespread adoption in various applications.

Three-Coil Wireless Charging System Based on S-PS Topology

To protect the battery, radio energy transmission charging typically uses constant current (CC) charging before switching to constant voltage (CV) charging to enhance battery durability. This paper proposes adding an auxiliary clamp coil to the original circuit topology. The IPT battery charger designed with the auxiliary clamp coil can achieve both constant current (CC) and constant voltage (CV) outputs. The mutual inductance between the auxiliary clamp coil and the primary side coil greatly influences the output performance of the entire IPT system, so the auxiliary clamp coil should not be too large. To solve this problem, an S-S-PS circuit with secondary compensation topology in the secondary coil is proposed. This circuit topology reduces the size of the auxiliary clamp coil, allowing it to be placed in an optimal position. When the constant voltage output critical position is reached, the IPT system can still automatically, continuously, and smoothly switch between CC and CV modes. Consequently, this approach avoids increased cost consumption associated with detecting CC-CV switching thresholds, adding wireless transmission communication modules, real-time control of the power transmitter, and active protection of the circuit during constant current charging. Finally, a 48 V/2.5 A prototype was built to verify that the IPT system has CC-CV conversion functionality.

Fabrication electro-spun Poly(vinyl alcohol)-Melamine nonwoven membrane composite separator for high-power lithium-ion batteries

Current commercial separators used in lithium-ion batteries have inherent flaws, especially poor thermal stability, which pose substantial safety risks. This study introduces a high-safety composite membrane made from electrospun poly(vinyl alcohol)-melamine (PVAM) and polyvinylidene fluoride (PVDF) polymer solutions via a dip coating method, designed for high-voltage battery systems. The poly(vinyl alcohol) and melamine components enhance battery safety, while the PVDF coating improves lithium-ion conductivity. The dip-coated PVDF/Esp-PVAM composite separators were evaluated for electrolyte uptake, contact angle, thermal stability, porosity, electrochemical stability and ionic conductivity. Notably, our Dip 1 % PVDF@Esp-PVAM composite separator exhibited excellent wettability and a lithium-ion conductivity of approximately 7.75 × 10⁻⁴ S cm⁻1 at room temperature. These separators outperformed conventional PE separators in half-cells with Ni-rich NCM811 cathodes, showing exceptional cycling stability with 93.4 % capacity retention after 100 cycles at 1C/1C, as compared to 84.8 % for PE separators. Our Dip 1 % PVDF@Esp-PVAM composite separator demonstrates significant potential for enhancing the long-term durability and high-rate performance of lithium-ion batteries, making it a promising option for long-term energy storage applications.

Plasma-enhanced SnO2-x thin films on copper current collector for safer lithium metal batteries

Anode-free lithium batteries are a safer and lighter alternative, because they eliminate the traditional host anode for lithium ions, thereby enhancing energy density and reducing the battery weight. However, challenges like dendritic growth and electrolyte decomposition persist, affecting battery lifespan. Here, we present a scalable technique using plasma enhanced chemical vapor deposition (PECVD) of a tin(IV) precursor to directly deposit an artificial solid electrolyte interface (SEI) on the copper current collector. The obtained SnO2-x coatings, modified by oxygen plasma, exhibited remarkable electrochemical properties. X-ray photoelectron spectroscopy (XPS) is employed to examine the surface composition and impact of plasma treatment, while long-term cycling and electrochemical impedance spectroscopy (EIS) confirm battery durability. Scanning electron microscopy (SEM) and contact angle measurements elucidate coating homogeneity, with lithium nucleation overpotential during first cycle providing further evidence for homogeneity during lithium de-/plating.

Impedance-based online detection of lithium plating for lithium-ion batteries: Mechanism and sensitivity analysis

Lithium plating is one of the most severe problems threatening the durability and safety of lithium-ion batteries. Therefore, accurate detection of lithium plating is crucial for the health management and charging control of lithium-ion batteries. In this paper, an impedance-based method is proposed to detect lithium plating of lithium-ion battery by comparing the normalized charing internal resistance profiles. After verifying that the model-based method is effective and feasible, it was used to analyze the reason and internal mechanism of the detection signal compared with the more frequently used lithium plating detection procedures today. The proposed detection method is more sensitive and accurate and expected to detect lithium plating in real-time during the charging process. Finally, the model showed that the method remained effective and reliable for lithium plating detection when the charging conditions changed. This paper, through the analysis, simulation, and experimental verification of online lithium plating detection method based on charging internal resistance, provides innovative ideas for the subsequent development of lithium plating detection and stimulates potential technologies for future development.

Integration of Functional Groups to Enhance the Solubility and Stability of Viologen in Aqueous Organic Redox Flow Batteries.

The chemical stability and energy density of redox couples are crucial factors in enhancing the durability and cost competitiveness of aqueous flow batteries. This study proposed integrating functional groups to viologen anolyte to increase its solubility and, consequently, energy density and stability for prolonged performance. Specifically, sulfonate and ester groups were selectively incorporated at the nitrogen sites of viologen to enhance solubility, leveraging their asymmetry and double hydrophilicity. Furthermore, an alpha-methyl group was introduced between the bipyridine and ester groups to enhance the chemical stability by preventing stacking and dimerization that can lead to irreversible degradation. The modified viologen demonstrated a remarkable solubility of 3.0 M in deionized water, corresponding to a volumetric capacity of 80.404 Ah L-1. Additionally, the designed viologen exhibits outstanding retention of 92.4% after 200 cycles with a minimal capacity fading rate of 0.055% per cycle in a 0.1 M flow cell test.

Designing a Se-intercalated MOF/MXene-derived nanoarchitecture for advancing the performance and durability of lithium-selenium batteries

Lithium-selenium batteries have emerged as a promising alternative to lithium-sulfur batteries due to their high electrical conductivity and comparable volume capacity. However, challenges such as the shuttle effect of polyselenides and high-volume fluctuations hinder their practical implementation. To address these issues, we propose synthesizing Fe-CNT/TiO2 catalyst through high-temperature sintering of an amalgamated nanoarchitecture of carbon nanotubes decorated metal–organic framework (MOF) and MXene, optimized for efficient selenium hosting, leveraging the distinctive physicochemical properties. The catalytic features inherent in the porous Se@Fe-CNT/TiO2 nanoarchitecture were instrumental in promoting efficient ion and electron transport, and lithium-polyselenide kinetics, while its inherent porosity could play a crucial role in inhibiting electrode stress during cycling. This nanoarchitecture exhibits remarkable battery performance, retaining 99.7% of theoretical capacity after 425 cycles at 0.5 C rate and demonstrating 95.8% capacity retention after 2000 cycles at 1 C rate, with ∼100% Coulombic efficiency. Additionally, the Se@Fe-CNT/TiO2 electrode exhibited an impressive recovery of 297.5 mAh/g (97.9%) capacity after undergoing 450 cycles at a charging rate of 10 C and a discharging rate of 1 C. This synergistic integration of MOF- and MXene-derived materials unveils new possibilities for high-performance and durable LSeBs, thus advancing electrochemical energy storage systems.

A proactive energy management strategy for battery-powered autonomous systems

Battery energy management systems have been studied in control communities for many years. This paper proposes a new perspective by integrating control and scheduling for battery-powered autonomous systems. This is motivated by the observations that battery closed-loop control can significantly improve the DC-bus stability but reduce the battery durability, while load scheduling can considerably improve the battery durability by smoothing the load power. In view of the above findings, we propose a proactive energy management strategy for the battery energy management system to improve both the DC-bus stability and battery durability. We first analyze the schedulability of load tasks to check if they are schedulable. Then, the power of schedulable loads is scheduled with an active load scheduling algorithm to smooth the fluctuation of battery current and extend the battery lifetime. Thereafter, the scheduled load power is integrated with a feedforward control to restrain DC-bus voltage fluctuation. In addition to the classical sporadic/periodic load tasks model, we propose a new aperiodic load task model to characterize the load power triggered by events in practical applications. An experimental platform is built to verify the effectiveness of the proposed proactive energy management method. Experimental results show that the proposed proactive energy management method can suppress the 15.71% DC-bus voltage fluctuation and reduce the 8.93% battery current fluctuation, extending the battery lifetime by 7.57% compared to existing energy management strategies.

Interfacial "Double-Terminal Binding Sites" Catalysts Synergistically Boosting the Electrocatalytic Li2S Redox for Durable Lithium-Sulfur Batteries.

Catalytic conversion of polysulfides emerges as a promising approach to improve the kinetics and mitigate polysulfide shuttling in lithium-sulfur (Li-S) batteries, especially under conditions of high sulfur loading and lean electrolyte. Herein, we present a separator architecture that incorporates double-terminal binding (DTB) sites within a nitrogen-doped carbon framework, consisting of polar Co0.85Se and Co clusters (Co/Co0.85Se@NC), to enhance the durability of Li-S batteries. The uniformly dispersed clusters of polar Co0.85Se and Co offer abundant active sites for lithium polysulfides (LiPSs), enabling efficient LiPS conversion while also serving as anchors through a combination of chemical interactions. Density functional theory calculations, along with in situ Raman and X-ray diffraction characterizations, reveal that the DTB effect strengthens the binding energy to polysulfides and lowers the energy barriers of polysulfide redox reactions. Li-S batteries utilizing the Co/Co0.85Se@NC-modified separator demonstrate exceptional cycling stability (0.042% per cycle over 1000 cycles at 2 C) and rate capability (849 mAh g-1 at 3 C), as well as deliver an impressive areal capacity of 10.0 mAh cm-2 even in challenging conditions with a high sulfur loading (10.7 mg cm-2) and lean electrolyte environments (5.8 μL mg-1). The DTB site strategy offers valuable insights into the development of high-performance Li-S batteries.

Proton-selective coating enables fast-kinetics high-mass-loading cathodes for sustainable zinc batteries

The pressing demand for sustainable energy storage solutions has spurred the burgeoning development of aqueous zinc batteries. However, kinetics-sluggish Zn2+ as the dominant charge carriers in cathodes leads to suboptimal charge-storage capacity and durability of aqueous zinc batteries. Here, we discover that an ultrathin two-dimensional polyimine membrane, featured by dual ion-transport nanochannels and rich proton-conduction groups, facilitates rapid and selective proton passing. Subsequently, a distinctive electrochemistry transition shifting from sluggish Zn2+-dominated to fast-kinetics H+-dominated Faradic reactions is achieved for high-mass-loading cathodes by using the polyimine membrane as an interfacial coating. Notably, the NaV3O8·1.5H2O cathode (10 mg cm−2) with this interfacial coating exhibits an ultrahigh areal capacity of 4.5 mAh cm−2 and a state-of-the-art energy density of 33.8 Wh m−2, along with apparently enhanced cycling stability. Additionally, we showcase the applicability of the interfacial proton-selective coating to different cathodes and aqueous electrolytes, validating its universality for developing reliable aqueous batteries.

Study of Electroless Nickel Plating on Super Duplex Stainless Steel for Lithium-Ion Battery Cases: Electrochemical Behaviour and Effects of Plating Time

With increasing demand for Li-ion batteries, studies are focusing on enhancing battery performance and safety. However, studies on battery cases remain scarce. Herein, we propose the use of super duplex stainless steel SAF2507, which is a two-phase (austenite + ferrite) steel, for battery casings. Unlike conventional AISI304, SAF2507 maintains its corrosion resistance and strength at high temperatures and precipitates a secondary phase at approximately 975 °C. However, the effects of Ni plating on this secondary phase are not well documented. Therefore, the electroless Ni plating of SAF2507 after secondary-phase precipitation was studied. Briefly, heat treatment at 1000 °C was used to induce precipitation, and the electroless Ni plating behaviour over varying plating periods was analysed using open-circuit potential, potentiodynamic polarisation, and electrochemical impedance spectroscopy measurements. The plating state and corrosion behaviour were examined using scanning electron microscopy. Heat-treated SAF2507 steel with a secondary phase exhibited excellent electroless Ni plating behaviour, which enhances the safety and durability of Li-ion batteries. Furthermore, uniform plating and electrochemical behaviour were achieved after 180 s, suggesting that SAF2507 is superior to AISI304. These findings contribute to the development of safer and more efficient batteries and address the growing demand for Li-ion battery case materials.