The battery research and production process
Thermo Scientific systems touch every part of the battery value chain, from extraction and processing of raw materials, to quality assurance in the production line, to research and development of new battery designs.
Battery mineral resource processing
Selected use cases for battery mineral processing
Challenge |
Technologies |
Solution |
Resources |
Elemental analysis and grade control of nickel, cobalt, manganese, iron, lithium ores |
XRF |
Thermo Scientific XRF lab spectrometers can quantify up to 90 elements in liquid or solid samples of mining materials, enabling control of ore body content for refinement and processing |
App note: Analysis of Nickel Ore with ARL OPTIM'X WDXRF Spectrometer |
App note: EDXRF Analysis of Nickel Ore as Pressed Powders in an Air Environment |
|||
| App note: Analysis of lithium raw materials with WDXRF | |||
| App note: Manganese ore analysis with the ARL OPTIM’X XRF Spectrometer | |||
| App note: Iron ore analysis with the ARL OPTIM’X XRF Spectrometer |
Abbreviations: XRF = X-ray fluorescence.
Battery raw materials control
Selected use cases for battery raw materials control
Challenge |
Technologies |
Solution |
Resources |
Electrode materials QC requires higher resolution than OM, but floor-based SEMs won’t fit in our lab and manual analysis is too slow |
Desktop SEM |
The Thermo Scientfic Phenom XL Desktop SEM can handle high-resolution morphology analysis and QC of anode and cathode materials with high-throughput automation |
|
Identification and quantification of metal impurities in raw materials is critical, but neither ICP nor optical microscopy does both |
Desktop SEM, EDS |
Thermo Scientfic Phenom ParticleX Desktop SEM can identify and quantify particle impurities with high-throughput automated EDS workflow |
Webinar: How to certify your NCM powder quality with SEM+EDS |
Rapidly characterize lithium, metal oxide, and lithium compounds |
Raman |
Thermo Scientific Raman instruments can analyze these compounds quickly with minimal sample preparation |
Blog post: Using Raman spectroscopy during lithium-ion battery manufacturing |
Characterize lithium and other highly reactive salts |
FTIR |
Compact Thermo Scientfic Nicolet FTIR instruments can measure sample spectra within an argon-purged glove box using remote control |
App note: FTIR characterization of lithium salts in an inert atmosphere |
Characterize raw materials |
XPS |
XPS can be used to analyze the surface of powdered materials prior to formation of electrodes, determining stoichiometry and identifying contaminants |
|
Evaluate purity of raw materials |
XRF |
Elemental analysis from ppm to 100%, pre-screening for impurities in carbon black |
|
Identify and quantify mineral composition in raw materials |
XRD |
Phase identification and structure determination in anode and cathode |
Abbreviations: EDS = Energy-dispersive X-ray spectroscopy; FTIR = Fourier transform infrared spectroscopy; ICP = Inductively coupled plasma; OM = Optical microscopy; SEM = Scanning electron microscopy; XRD = X-ray diffraction; XRF = X-ray fluorescence.
Battery production applications
Selected use cases for battery production
Challenge |
Technologies |
Solution |
Resources |
Detection of electrode impurities is slow and tedious using normal SEM-to-EDS workflow |
ChemiSEM, EDS |
Thermo Scientfic Axia ChemiSEM integrates SEM with “live EDS” for immediate characterization of electrode impurities |
App note: Assessment of contaminants within battery materials via Axia ChemiSEM |
Failure analysis and QC in battery production requires SEM-level resolution, but floor models take too much space |
Desktop SEM |
Phenom Desktop SEMs enable high-resolution, high-throughput analysis of battery materials |
App note: Investigate batteries with a SEM for better performance |
Identification and quantification of metal impurities in raw materials is critical, but neither ICP nor OM does both |
Desktop SEM, EDS |
Phenom ParticleX Desktop SEM can identify and quantify particle impurities with high-throughput automated EDS workflow |
Webinar: How to certify your NCM powder quality with SEM+EDS |
Binder characterization is difficult but crucial to confirm electrode mechanical structure |
SEM, DualBeam |
Superior imaging contrast of unique T3 detector for Thermo Scientfic Apreo 2 SEM enables mapping of non-conductive binder distribution within electrode |
Brochure: Scanning electron microscopy for lithium battery research |
Simultaneously quantify major elements (% level) and trace impurities (ppm, mg/kg) of a battery cathode |
ICP-OES |
Thermo Scientfic iCAP 6000 Series ICP-OES can accurately measure concentrations in solutions ranging from <0.006 mg/L to nearly 3000 mg/L (6 orders of magnitude) |
|
Battery slurries mixed batchwise in planetary mixers is labor-intensive, has low material efficiency, and bears the risk of batch-to-batch variations.
Electrodes coated by solvent-casting methods requires energy consumptive solvent evaporation and recycling techniques. Volatile solvents are hazardous and expensive. |
Twin-screw Extrusion | Continuous slurry compounding reduces material loss, cleaning time, handling errors, and product variations. Thermo Scientific twin-screw extruders continuously compound slurries with high reproducibility. Control composition, material shear, and temperatures.
PTFE acts as a binder in solvent-free electrode slurries. Compounding of PTFE and active material powders requires high shear. Thermo Scientific twin-ccrew extruders successfully compound PTFE and active material to produce solvent-free slurries. High shear renders formation of PTFE fibrils binding active material grains |
On-demand webinar: Compound homogeneous electrode slurries fast and effectively |
Abbreviations: DualBeam = Focused ion beam scanning electron microscopy (FIB-SEM); EDS = Energy-dispersive X-ray spectroscopy; FIB = Focused ion beam; ICP = Inductively coupled plasma; NCM = Nickel cobalt manganese; OES = Optical emission spectrometry; OM = Optical microscopy; SEM = Scanning electron microscopy.
Battery quality control
Selected use cases for battery QA/QC
Challenge |
Technologies |
Solution |
Resources |
Identification of impurities for root cause analysis is difficult using CT alone |
CT/SDB, EDS, Avizo |
A correlative CT/laser PFIB workflow can identify deeply embedded impurities without disassembling the cell |
App note: Multiscale 3D imaging solutions for Li-ion batteries |
Failure analysis requires high-resolution cross-section polishing while still protecting sample |
SEM, CleanMill |
Thermo Scientfic CleanMill offers a dedicated workflow for air-sensitive samples, an ultra-high energy ion gun for fast polishing, and a cryogenic function to protect sample integrity |
|
Differentiate carbon allotropes, reveal anode material structure, and track changes during usage |
Raman |
Raman spectroscopy is particularly useful for distinguishing between different allotropes of carbon and evaluating the structural quality of these materials |
App note: Raman analysis of lithium-ion batteries – Part II: Anodes |
Map degradation of the anode SEI layer |
Raman |
Raman microscopy can be used for visualizing changes to electrode materials and component distributions after a cell has been used |
|
Monitor battery off-gassing or chemicals released during a fire, short circuit, or other hazardous conditions |
FTIR |
Thermo Scientfic Antaris IGS system with Heated Valve Drawer can quantify release of HF and other fluorinated gasses under overtaxed conditions like a vehicle crash |
|
Assess crystallinity, stability, and reactivity in battery materials |
XRD |
Check crystal structure, crystallinity, orientation characteristics, thickness, homogeneity, and density of thin films and layers |
|
Detect defects, inclusions, and imperfections |
XRF |
Elemental mapping and small spot analysis down to 0.5 mm |
App note: Sample analysis using elemental mapping at low power with Thermo Scientific ARL PERFORM’X 1500 W Advanced WDXRF Spectrometer |
App note: Sample analysis using mapping with ARL PERFORM’X Series XRF spectrometers |
|||
Control the purity of anodes, cathodes, electrolytes, separators, and other components |
XRF |
Wavelength dispersive X-ray fluorescence (WDXRF) allows routine, daily monitoring and control of impurities and contamination |
|
Quantify trace elements in lead and lead alloys according to current standards for lead-acid batteries |
OES |
The Thermo Scientfic ARL iSpark Optical Emission Spectrometer enables trace and alloying element analysis in lead-acid batteries |
Analysis of lead and its alloys with the ARL iSpark OES spectrometer |
Understanding the rheological properties of an electrode slurry is necessary to:
|
Rotational Rheometry | Characteristic flow curves (the slurry viscosity over shear rate) provide insight of the slurries' flow behavior in processes like pumping, stirring, and coating. Thermo Scientific HAAKE iQ Air Rotational Rheometers are used to measure flow curves over a broad range of shear rates with high precision. | On-demand webinar: Rotational Rheology in Battery Manufacturing and Research |
Abbreviations: DualBeam = Focused ion beam scanning electron microscopy (FIB-SEM); EDS = Energy-dispersive X-ray spectroscopy; FIB = Focused ion beam; ICP = Inductively coupled plasma; NCM = Nickel cobalt manganese; OES = Optical emission spectrometry; OM = Optical microscopy; SEM = Scanning electron microscopy.
Battery recycling
Selected use cases for battery recycling
Challenge |
Technologies |
Solution |
Resources |
Recycled materials QC requires higher resolution than OM, but floor-based SEMs won’t fit in our lab and manual analysis is too slow |
Desktop SEM |
The Phenom XL Desktop SEM can handle high-resolution QC of recycled battery materials with high-throughput automation |
|
Identification and quantification of metal impurities in recycled materials is critical, but neither ICP nor OM does both |
Desktop SEM, EDS |
The Phenom ParticleX Desktop SEM can identify and quantify particle impurities with high-throughput automated EDS workflow |
Webinar: How to certify your NCM powder quality with SEM+EDS |
Sort incoming materials to be recycled and control impurities in recovered metals |
XRF |
Black mass elemental analysis for recovery of metals, such as aluminum, nickel, cobalt, manganese and graphite. |
App note: Analysis of traces in graphite |
Abbreviations: EDS = Energy-dispersive X-ray spectroscopy; ICP = Inductively coupled plasma; OM = Optical microscopy; SEM = Scanning electron microscopy; XRF = X-ray fluorescence.
For Research Use Only. Not for use in diagnostic procedures.