The understanding of the phenomena occurring during immersion of LiNi0.5Mn0.3Co0.2O2 (NMC) in water is helpful to devise new strategies toward the implementation of aqueous processing of this high-capacity cathode material. Immersion of NMC powder in water leads to both structural modification of the particles surface as observed by high-resolution scanning transmission electron microscopy and the formation of lithium-based compounds over the surface (LiOH, Li2CO3) in greater amount than after long-time exposure to ambient air, as confirmed by pH titration and 7Li MAS NMR analysis. The surface compounds adversely affect the electrochemical performance and are notably responsible for the alkaline pH of the aqueous slurry, which causes corrosion of the aluminum collector during coating of the electrode. The corrosion is avoided by adding phosphoric acid to the slurry as it lowers the pH, and it also enhances the cycling stability of the water-based electrodes due to the phosphate compounds formed at the particles surface, as evidenced by X-ray photoelectron spectroscopy analysis.

Herein we report, for the first time, an overall evaluation of commercially available battery separators to be used for aluminum batteries, revealing that most of them are not stable in the highly reactive 1-ethyl-3-methylimidazolium chloride:aluminum trichloride (EMIMCl:AlCl) electrolyte conventionally employed in rechargeable aluminum batteries. Subsequently, a novel highly stable polyacrylonitrile (PAN) separator obtained by the electrospinning technique for application in high-performance aluminum batteries has been prepared. The developed PAN separator has been fully characterized in terms of morphology, thermal stability, and air permeability, revealing its suitability as a separator for battery applications. Furthermore, extremely good compatibility and improved aluminum interface stability in the highly reactive EMIMCl:AlCl electrolyte were discovered. The use of the PAN separator strongly affects the aluminum dissolution/deposition process, leading to a quite homogeneous deposition compared to that of a glass fiber separator. Finally, the applicability of the PAN separator has been demonstrated in aluminum/graphite cells. The electrochemical tests evidence the full compatibility of the PAN separator in aluminum cells. Furthermore, the aluminum/graphite cells employing the PAN separator are characterized by a slightly higher delivered capacity compared to those employing glass fiber separators, confirming the superior characteristics of the PAN separator as a more reliable separator for the emerging aluminum battery technology.