Cobalt-free
spinel LiNi0.5Mn1.5O4 is one of the
most promising and environmentally friendly cathodes,
based on its high specific theoretical capacity (147 mAh·g–1) and high electrochemical potential (4.7 V vs Li+/Li), as well as good electronic and Li-ion
conductivities. In this work, we present the fabrication of LiNi0.5Mn1.5O4 thin-film cathodes deposited
by the industrially scalable AC magnetron sputtering technique on
functional and cost-effective stainless steel current collectors.
This is the first step toward battery downscaling, envisioning the
fabrication of compact microbatteries for low-power energy supply.
The thin-film strategy is crucial also for solid electrolyte fabrication
that will allow the integration of high-energy-density batteries while
overcoming most of the current battery challenges. In this work, the
effect of film thickness on the material’s electrochemical
performance is discussed, correlating the observed structural and
morphological evolution with the final electrochemical response. Moreover,
the effect of iron diffusion from the current collector substrate
into the cathode film is analyzed. The addition of a stable CrN barrier
layer in between the substrate and the film is proposed to prevent
Fe diffusion, with a direct positive influence on the electrochemical
behavior. All in all, the obtained results will facilitate the practical
implementation of LiNi0.5Mn1.5O4 thin
films as high-voltage cathodes in functional cost-effective microbatteries.