Battery Research and Manufacturing | Battery Applications

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 research applications

Selected use cases for battery research

Challenge	Technologies	Solution	Resources
Avoid contamination of air-, moisture-, and/or beam-sensitive battery samples during preparation and sample transfer	IGST workflow: DualBeam, SEM/Desktop SEM (in glove box), TEM, Avizo, CleanConnect	Complete workflow to enable sample characterization of sensitive battery materials in their native state without contamination	Brochure: Seamless inert gas sample transfer workflow
			Datasheet: CleanConnect Sample Transfer System
			App note: Benefits of the Phenom XL G2 Desktop SEM's argon compatibility for lithium battery research
Detection of lithium is difficult using SEM, EDS, and TEM	TOF-SIMS	Accurately detect and map lithium in battery samples in 2D and 3D down to 10 ppm	App note: Ion spectroscopy using TOF-SIMS on a Thermo Scientific Helios DualBeam
	TEM	iDPC technology can clearly image light elements like lithium at atomic scale	App note: Integrated Differential Phase Contrast on Talos S/TEM
Characterize battery structure at different scales beyond the capacity of a single instrument	CT, SEM, Raman, DualBeam, Avizo, EDS	Correlative workflow allowing multiscale imaging and analysis of battery microstructure	App note: Multiscale image-based control and characterization of lithium-ion batteries
	CT, SEM, Raman, DualBeam, Avizo, EDS		App note: Multiscale 3D imaging solutions for Li-ion batteries
Prepare a large 2D area on the sample surface with high polishing quality for 2D imaging and characterization	DualBeam (Plasma FIB-SEM), EDS	High-throughput automated spin mill with high surface quality	App note: Large area automated sample preparation for batteries
	SEM, CleanMill	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	Datasheet: CleanConnect Sample Transfer System
Characterize key microstructure properties (like tortuosity) for electrode structure performance correlations	DualBeam, EDS, TOF-SIMS, Avizo	3D characterization of battery structure · Hardware to image 3D battery structure at different scales · Software to automate 3D imaging data collection · Thermo Scientific Avizo Software workflow for image analysis and quantification	Blog post/video: Advancing lithium-ion battery technology with 3D imaging
	DualBeam, EDS, TOF-SIMS, Avizo		App note: Multiscale image-based control and characterization of lithium-ion batteries
Characterize beam-sensitive materials like SEI at nanoscale	TEM, EDS, Avizo	Nano- and atomic-scale characterization of energy materials · Cryo-EM workflow for accurate data collection with superior EDS performance · Avizo Software for structure quantification and visualization	Brochure: Analytical solutions for battery and energy storage technology
			Webinar: Cryo- and in situ electron microscopy diagnosis-guided design of rechargeable battery materials for better batteries
			Webinar: Advanced characterization methods of electrochemical materials and interphases for better batteries
In situ kinetic analysis (like heating) via electron microscope	SEM	Multiple in situ heating stage choices with integrated software for Thermo Scientific SEMs to understand cathode synthesis mechanisms	Brochure: Scanning electron microscopy for lithium battery research
Characterize beam-sensitive separator samples without damage	SEM/SDB	Superior low-KeV imaging and a cryo-FIB milling solution allow characterization of separator microstructure in 2D and 3D	App note: Strategies for accurate imaging on battery separator structure
Probe intrinsic SEI within a coin cell via electron microscopy	Laser Plasma FIB	High-energy, high-milling rate laser enables direct cross-section milling to understand Li-metal cell degradation mechanism	Webinar: Visualizing Li-metal anode battery degradation
Understand stoichiometry of solid electrolyte film as a function of depth	XPS	XPS depth profiling can quantify elements at each depth
	XPS	XPS depth profiling can quantify elements at each depth	Webinar: Understanding surface reactions of the solid electrolyte interface via advanced characterization techniques
Measure electrode surface chemistry	XPS	XPS can quantify the chemical states present at the electrode surface	App note: Analysis of electrode materials for lithium ion batteries
Track the evolution of the SEI layer	XPS	Materials can be depth profiled using XPS and a cluster ion source to follow the development of the SEI layer after cycling
In situ electrode cycling	XPS	Electrodes can be operated in situ to monitor spectral changes as they are charged and discharged
Investigate changes in separator chemistry during cell lifetime	XPS	The surface chemistry of polymeric materials is easily characterized using XPS
Profile battery components ex situ without missing point-to-point variability across an area	Raman	Raman microscopy can be used to look at changes to materials and distributions of components that occurred during use or testing	App note: Ex situ Raman analysis of Li-ion batteries
Identify phases and determine structures in anodes and cathodes	Raman	Raman microscopy can visually show the spatial distribution of different phases of the same material with different performance characteristics	App note: Raman analysis of lithium-ion batteries – Part I: Cathodes
	Raman		App note: Raman analysis of lithium-ion batteries – Part II: Anodes
	XRD	XRD can help to identify and quantify specific polymorphic structures of interest to increase yield and efficiency	Brochure: ARL EQUINOX 100 X-ray Diffractometers
Trace and map anode composition across charge and discharge cycles	Raman	Raman microscopy can be used for in situ monitoring of changes on electrode surfaces during charge/discharge cycles	App note: In situ Raman analysis of Li-ion batteries
Confirm the presence of specific carbon allotropes as anode components and in hybrid materials	Raman	Raman spectroscopy is particularly adept at the analysis of allotropes of carbon, including carbon in hybrid materials	App note: Raman analysis of lithium-ion batteries – Part II: Anodes
Understand the association of ionic species and distribution of components in solid polymer electrolytes (SPEs)	Raman	Raman microscopy can be used to visualize the spatial distribution of components in SPEs and indicate ionic associations	App note: Raman analysis of lithium-ion batteries – Part III: Electrolytes
Study crystallinity, stability, and reactivity in battery materials	XRD	X-ray diffraction can determine the percentage of crystallinity vs amorphous content of the active material, as well as structural stability and repeatability in real time	Brochure: ARL EQUINOX 100 X-ray Diffractometers
Follow charge/discharge reactions in situ	XRD	During charge/discharge, the cathode and anode of every battery cell undergo changes. XRD allows you to follow the changing phase composition and the evolution of the crystalline structure	Webinar: Drill down to microstructures with XRD

Abbreviations: Avizo = Avizo Software; CT = Computed tomography; DualBeam = Focused ion beam scanning electron microscopy (FIB-SEM); EDS = Energy-dispersive X-ray spectroscopy; FIB = Focused ion beam; FTIR = Fourier transform infrared spectroscopy; iDPC = Integrated differential phase contrast; IGST = Inert sample gas transfer; SDB = Small DualBeam; SEI = Solid electrolyte interface; SEM = Scanning electron microscopy; SPE = Solid polymer electrolytes; TEM = Transmission electron microscopy; TOF-SIMS = Time of flight secondary ion mass spectrometry; XPS = X-ray photoelectron spectroscopy; XRD = X-ray diffraction.

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
	Desktop SEM		Blog post: Analysis of graphite for lithium-ion batteries
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	Brochure: X-ray Product Range
Identify and quantify mineral composition in raw materials	XRD	Phase identification and structure determination in anode and cathode	Brochure: ARL EQUINOX 100 X-ray Diffractometers

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)	App note: Simultaneous determination of impurities and major elements in lithium-ion battery cathodes using the Thermo Scientific iCAP 6000 Series Radial ICP-OES
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	Datasheet: CleanConnect Sample Transfer System
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	App note: Ex situ Raman analysis of Li-ion batteries
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	Tech note: Gas-phase FTIR for smoke toxicity measurements
Assess crystallinity, stability, and reactivity in battery materials	XRD	Check crystal structure, crystallinity, orientation characteristics, thickness, homogeneity, and density of thin films and layers	Brochure: ARL EQUINOX 100 X-ray Diffractometers
Detect defects, inclusions, and imperfections	XRF	Elemental mapping and small spot analysis down to 0.5 mm	App note: Small spot analysis: Performance in ferrous base
			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	App note: Analysis of traces in graphite
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: Optimize the coating process Define the storage handling Characterize the quality of dispersion as a predictor for cell performance.	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

Explore battery QA/QC

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.

Battery Research and Manufacturing Applications