Name
Technical Session XIII - MSEC-155785
Date & Time
Thursday, June 26, 2025, 3:55 PM - 4:20 PM
Description
Economic and technological advancements and the expansion of the global population have led to a tremendous spike in energy demands. Battery-operated stationary energy storage systems are currently the prevalent energy storage solutions. Beyond their use in stationary energy storage systems, lithium-ion batteries (LIBs) are extensively utilized in portable electronic devices, electric vehicles (EV), and hybrid electric vehicles (HEV). Enhancing the overall electrochemical performance, including capacity, lifetime, safety, and power density, relies on battery manufacturing methods. Conventional electrode fabrication methods are incompetent in meeting the shape, size, control over all features, and form factor requirements of advanced 3D batteries. 3D printing, a transformative manufacturing technology, has emerged as a ground-breaking method for fabricating battery electrodes across various scales, from nanoscale to macroscale. The additive manufacturing (AM) characteristic of 3D printing offers superior control over device geometry, such as electrode thickness and porosity, through a much morestreamlined and cost-effective procedure. Among the seven sub-categories of AM, laser powder bed fusion (L-PBF) emerges as a compelling choice for fabricating metal-based structural battery electrodes. L-PBF is an efficient and economical production technique that offers the advantage of being suitable for a range of raw materials, facilitating the creation of hierarchical porous structures and functionally graded materials. This study presents the fabrication of a highly porous metallic face-centered cubic (FCC) latticestructure through the L-PBF process, intended as a core framework for developing structural batteries. The cross-tilted ligaments of truss-type FCC lattices provide a high surface area, increasing mechanical strength and thermal conductivity. AlSi10Mg powder was chosen as the raw material for L-PBF fabrication due to its growing application in the automotive, aerospace, and construction industries, attributed to its excellent physical and mechanical properties. The powder particles exhibit a nearly spherical morphology, with sizes ranging from 1 to 34 micrometers. The EOS-M280 metal 3D printer facilitated the fabrication of the porous structure, functioning within an argon-inert gas environment and employing a continuous 370 W Ytterbium (Yb) fiber laser beam. Each unit cell was constructed to have dimensions of 8 mm, with the lattice structure configured as a cube with sides measuring 24 mm. The fabricated samples underwent metrological evaluations, including optical microscopy (OM), as well as material characterizations like scanning electron microscopy (SEM) and X-ray diffractometry (XRD). Zinc oxide (ZnO) was selected as an active electrode due to its outstanding electrochemical properties and ease of processing. ZnO was deposited over the metal-based porous FCC structures using the dip coating and thermal treatment. Lithium chloride (LiCl) was selected as the electrolyte as lithium-based electrolytes demonstrate superior ionic conductivities attributed to the enhanced mobility of the lithium cations. The battery performance of the developed electrodes was performed using different electrochemical characterizations like cyclic voltammetry (CV) and galvanostatic charge-discharge (GCD) tests. The electrochemical evaluations were conducted in a 1M LiCl electrolyte utilizing a three-electrode configuration using a GAMRY Potentiostat 1010E. The L-PBF fabricated ZnO electrodes exhibited animpressive energy density of 0.0591 Wh kg-1 and amaximum power density of 0.5985 W kg-1 at a current density of 3.311 mA g-1. The developedelectrodes demonstrated a remarkable capacity retention of approximately 95 % over 1500 charge-discharge cycles. The LPBF fabricated battery structures have immense potential for next-generation structural electronics.
Location Name
Magnolia
Full Address
Hyatt Regency
220 N Main St
Greenville, SC 29601
United States
220 N Main St
Greenville, SC 29601
United States
Session Type
Technical Session
Paper #
MSEC-155785
Author List
Nobel Karmakar, C. S. Kumar, Poonam Sundriyal
Paper Title
Fabrication of Alsi10mg Lattice Structure as Battery Electrodes via Laser Powder Bed Fusion Process
Session Chair
Muyue (Margret) Han