Driving range and fast charge capability of electric vehicles are heavily dependent on the 3D microstructure of lithium-ion batteries (LiBs) and substantial fundamental research is required to optimise electrode design for specific operating conditions. Here we have developed a full microstructure-resolved 3D model using a novel X-ray nano-computed tomography (CT) dual-scan superimposition technique that captures features of the carbonbinder domain. This elucidates how LiB performance is markedly affected by microstructural heterogeneities, particularly under high rate conditions. The elongated shape and wide size distribution of the active particles not only affect the lithium-ion transport but also lead to a heterogeneous current distribution and non-uniform lithiation between particles and along the through-thickness direction. Building on these insights, we propose and compare potential graded-microstructure designs for next-generation battery electrodes. To guide manufacturing of electrode architectures, in-situ X-ray CT is shown to reliably reveal the porosity and tortuosity changes with incremental calendering steps.

Operando microbeam Raman spectroscopy is used to map the changes in hard carbon during sodiation and desodiation in unprecedented detail, elucidating several important and unresolved aspects of the sodiation mechanism. On sodiation a substantial, reversible decrease in G-peak energy is observed, which corresponds directly to the sloping part of the voltage profile and we argue can only be due to steady intercalation of sodium between the turbostratic layers of the hard carbon. Corresponding reversibility of the D-peak energy change is consistent with intercalation rather than representing a permanent increase in disorder. No change in energy of the graphitic phonons occurs over the low voltage plateau, indicating that intercalation saturates before sodium clusters form in micropores in this region. At the start of the initial sodiation there is no change in G-and D-peak energy as the Solid Electrolyte Interphase (SEI) forms. After SEI formation, the background slope of the spectra increases irreversibly, due to fluorescence. The importance of in situ/operando experiments over ex situ studies is demonstrated; washing the samples or air exposure causes the G-and D-peaks to revert back to their original states owing to SEI removal and sodium de-intercalation and confirming no permanent damage to the carbon structure.

Graphite is the most commonly used anode material in commercial lithium-ion batteries (LiBs). Understanding the mechanisms driving the dimensional changes of graphite can pave the way to methods for inhibiting degradation pathways and possibly predict electrochemical performance loss. In this study, correlative microscopy tools were used alongside electrochemical dilatometry (ECD) to provide new insights into the dimensional changes during galvanostatic cycling. X-ray computed tomography (CT) provided a morphological perspective of the cycled electrode so that the effects of dilation and contraction on effective diffusivity and electrode pore phase volume fraction could be examined. During the first cycle, the graphite electrode underwent thickness changes close to 9% after lithiation and, moreover, it did not return to its initial thickness after subsequent delithiation. The irreversible dilation increased over subsequent cycles. It is suggested the primary reason for this dilation is electrode delamination. This is supported by the finding that the electrode porosity remained mostly unchanged during cycling, as revealed by X-ray CT.

This method for virtually unrolling the jelly roll of a lithium ion cell using X-ray CT highlights the predictability of macro deformations formed while cycling. The failure is shown to propagate from nucleation points present since production.