Novel Laser Sintering/Melting Method
University of Pittsburgh and Concurrent Technologies Corporation researchers are developing a Hybrid Variable Speed Sequential Cold Spray Laser Sintering/Melting (h-VSSCSLS/M) approach, a novel and transformative additive manufacturing technology. This approach uses artificial intelligence (AI) and machine learning (ML) digital twin (DT) concepts, aided by density functional theory (DFT) modelling to identify dopants, fabricate electrodes and other components with precision, control, and cost-efficiency compared to current slurry- or spray-based approaches.
Description
Lithium (Li)-ion batteries (LIBs) are increasingly used to provide greenhouse-gas-free energy storage. From consumer goods to electric cars, and even small aircraft, the Li-ion market is expanding. Current manufacturing methods for these batteries limit the ability to produce batteries with higher energy densities, specific capacity, and cyclability. The h-VSSCSLS/M approach could lead to the production of more reliable LIBs, enhance the properties of these batteries and other electrodes, reduce costs, and improve the energy and economic security of the Unites States.Applications
• Liquid electrolyte-based Li-ion batteries• Solid-state Li-ion batteries
• Biocompatible materials manufacturing
Advantages
Current manufacturing method for liquid electrolyte-based LIBs (LELIBs) rely on slurry-based approaches which limit packing densities, porosity and pore size distribution, the need to remove solvents and poor control at the current collector-electrode, and all vital electrode-electrolyte interfaces. All-Solid-State Li-ion Batteries (ASSLIBs) lack a universal fabrication approach with methods being complex and tedious, producing very thin, incoherent structures.h-VSSCSLS/M uses AI, ML and DT approaches to produce higher energy and power density LELIB electrodes and entire ASSLIBs with precise thickness, porosity, grain size, composition and phase control. This technique removes the need for solvents and binders traditionally used in fabrication and does not require clean rooms making this method cost-effective. Additionally, h-VSSCSLS/M can produce novel dendrite-free metal alloys, preventing a known fire risk in current LIBs and has the potential to additively manufacture complex structures of any polymer, ceramic, or metal.