Highly Ordered Eutectic Mesostructures via Template-Directed Solidification within Thermally Engineered Templates.

Template-directed self-assembly of solidifying eutectics results in emergence of unique microstructures due to diffusion constraints and thermal gradients imposed by the template. Here, the importance of selecting the template material based on its conductivity to control heat transfer between the template and the solidifying eutectic, and thus the thermal gradients near the solidification front, is demonstrated. Simulations elucidate the relationship between the thermal properties of the eutectic and template and the resultant microstructure. The overarching finding is that templates with low thermal conductivities are generally advantageous for forming highly organized microstructures. When electrochemically porosified silicon pillars (thermal conductivity < 0.3 Wm-1K-1) are used as the template into which an AgCl-KCl eutectic is solidified, 99% of the unit cells in the solidified structure exhibit the same pattern. In contrast, when higher thermal conductivity crystalline silicon pillars (≈100 Wm-1K-1) are utilized, the expected pattern is only present in 50% of the unit cells. The thermally engineered template results in mesostructures with tunable optical properties and reflectances nearly identical to the simulated reflectances of perfect structures, indicating highly ordered patterns are formed over large areas. This work highlights the importance of controlling heat flows in template-directed self-assembly of eutectics.

Relative Kinetics of Solid-State Reactions: The Role of Architecture in Controlling Reactivity.

Countless inorganic materials are prepared via high temperature solid-state reaction of mixtures of reagents powders. Understanding and controlling the phenomena that limit these solid-state reactions is crucial to designing reactions for new materials synthesis. Here, focusing on topotactic ion-exchange between NaFeO2 and LiBr as a model reaction, we manipulate the mesoscale reaction architecture and transport pathways by changing the packing and interfacial contact between reagent particles. Through analysis of in situ synchrotron X-ray diffraction data, we identify multiple kinetic regimes that reflect transport limitations on different length scales: a fast kinetic regime in the first minutes of the reaction and a slow kinetic regime that follows. The fast kinetic regime dominates the observed reaction progress and depends on the reagent packing; this challenges the view that solid-state reactions are necessarily slow. Using a phase-field model, we simulated the reaction process and showed that particles without direct contact to the other reactant phases experience large reduction in the reaction rate, even when transport hindrance at particle-particle contacts is not considered.

Enabling the electrochemical simulation of Li-ion battery electrodes with anisotropic tortuosity in COMSOL MultiphysicsⓇ.

Li-ion battery electrodes, such as widely used graphite anodes, may have anisotropic tortuosity due to the non-equiaxed shape of the active material particles and the post-casting calendaring process. Such anisotropy can be ignored in conventional electrodes because all the macroscopic ion transport occurs along the electrode thickness, making the ion transport effectively one dimensional. However, the anisotropy becomes important to consider with three-dimensional architectures, such as those generated by laser-patterning. COMSOL MultiphysicsⓇ is one of the leading tools used by the Li-ion battery modeling community to simulate the electrochemical dynamics of the Li-ion batteries. However, in its current implementation of the underlying model equations, the Li-ion battery module in COMSOL 5.4 cannot be used to simulate the electrochemical behavior of an electrode with anisotropic tortuosity. In this work, we show how the current implementation can be modified to simulate the anisotropic case.•The existing Li-ion battery model in COMSOL 5.4 was extended to account for the anisotropy in the electrode tortuosity•The extended model is necessary to accurately simulate the electrochemical dynamics of 3D architectures such as Highly ordered laser-patterned electrode (HOLE)•The testing and validation results are included in this work.

Grain boundary formation through particle detachment during coarsening of nanoporous metals.

Grain boundary formation during coarsening of nanoporous gold (NPG) is investigated wherein a nanocrystalline structure can form by particles detaching and reattaching to the structure. MicroLaue and electron backscatter diffraction measurements demonstrate that an in-grain orientation spread develops as NPG is coarsened. The volume fraction of the NPG sample is near the limit of bicontinuity, at which simulations predict that a bicontinuous structure begins to fragment into independent particles during coarsening. Phase-field simulations of coarsening using a computationally generated structure with a volume fraction near the limit of bicontinuity are used to model particle detachment rates. This model is tested by using the measured NPG structure as an initial condition in the phase-field simulations. We predict that up to ∼5% of the NPG structure detaches as a dealloyed [Formula: see text] sample is annealed at 300 °C for 420 min. The quantity of volume detached is found to be highly dependent on the volume fraction and volume fraction homogeneity of the nanostructure. As the void phase in the experiments cannot support independent particles, they must fall and reattach to the structure, a process that results in the formation of new grain boundaries. This particle reattachment process, along with other classic processes, leads to the formation of grain boundaries during coarsening in nanoporous metals. The formation of grain boundaries can impact a variety of applications, including mechanical strengthening; thus, the consideration and understanding of particle detachment phenomena are essential when studying nanoporous metals.

Simulation of the Electrochemical Impedance in a Three-Dimensional, Complex Microstructure of Solid Oxide Fuel Cell Cathode and Its Application in the Microstructure Characterization.

Electrochemical impedance spectroscopy (EIS) is a powerful technique for material characterization and diagnosis of the solid oxide fuel cells (SOFC) as it enables separation of different phenomena such as bulk diffusion and surface reaction that occur simultaneously in the SOFC. In this work, we simulate the electrochemical impedance in an experimentally determined, three-dimensional (3D) microstructure of a mixed ion-electron conducting (MIEC) SOFC cathode. We determine the impedance response by solving the mass conservation equation in the cathode under the conditions of an AC load across the cathode's thickness and surface reaction at the pore/solid interface. Our simulation results reveal a need for modifying the Adler-Lane-Steele model, which is widely used for fitting the impedance behavior of a MIEC cathode, to account for the difference in the oscillation amplitudes of the oxygen vacancy concentration at the pore/solid interface and within the solid bulk. Moreover, our results demonstrate that the effective tortuosity is dependent on the frequency of the applied AC load as well as the material properties, and thus the prevalent practice of treating tortuosity as a constant for a given cathode should be revised. Finally, we propose a method of determining the aforementioned dependence of tortuosity on material properties and frequency by using the EIS data.

A thermal-gradient approach to variable-temperature measurements resolved in space.

Temperature is a ubiquitous environmental variable used to explore materials structure, properties and reactivity. This article reports a new paradigm for variable-temperature measurements that varies the temperature continuously across a sample such that temperature is measured as a function of sample position and not time. The gradient approach offers advantages over conventional variable-temperature studies, in which temperature is scanned during a series measurement, in that it improves the efficiency with which a series of temperatures can be probed and it allows the sample evolution at multiple temperatures to be measured in parallel to resolve kinetic and thermodynamic effects. Applied to treat samples at a continuum of tem-peratures prior to measurements at ambient temperature, the gradient approach enables parametric studies of recovered systems, eliminating temperature-dependent structural and chemical variations to simplify interpretation of the data. The implementation of spatially resolved variable-temperature measurements presented here is based on a gradient-heater design that uses a 3D-printed ceramic template to guide the variable pitch of the wire in a resistively heated wire-wound heater element. The configuration of the gradient heater was refined on the basis of thermal modelling. Applications of the gradient heater to quantify thermal-expansion behaviour, to map metastable polymorphs recovered to ambient temperature, and to monitor the time- and temperature-dependent phase evolution in a complex solid-state reaction are demonstrated.

Archimedean lattices emerge in template-directed eutectic solidification.

Template-directed assembly has been shown to yield a broad diversity of highly ordered mesostructures1,2, which in a few cases exhibit symmetries not present in the native material3-5. However, this technique has not yet been applied to eutectic materials, which underpin many modern technologies ranging from high-performance turbine blades to solder alloys. Here we use directional solidification of a simple AgCl-KCl lamellar eutectic material within a pillar template to show that interactions of the material with the template lead to the emergence of a set of microstructures that are distinct from the eutectic's native lamellar structure and the template's hexagonal lattice structure. By modifying the solidification rate of this material-template system, trefoil, quatrefoil, cinquefoil and hexafoil mesostructures with submicrometre-size features are realized. Phase-field simulations suggest that these mesostructures appear owing to constraints imposed on diffusion by the hexagonally arrayed pillar template. We note that the trefoil and hexafoil patterns resemble Archimedean honeycomb and square-hexagonal-dodecagonal lattices6, respectively. We also find that by using monolayer colloidal crystals as templates, a variety of eutectic mesostructures including trefoil and hexafoil are observed, the former resembling the Archimedean kagome lattice. Potential emerging applications for the structures provided by templated eutectics include non-reciprocal metasurfaces7, magnetic spin-ice systems8,9, and micro- and nano-lattices with enhanced mechanical properties10,11.

Quantifying Reaction and Rate Heterogeneity in Battery Electrodes in 3D through Operando X-ray Diffraction Computed Tomography.

In composite battery electrode architectures, local limitations in ionic and electronic transport can result in nonuniform energy storage reactions. Understanding such reaction heterogeneity is important to optimizing battery performance, including rate capability and mitigating degradation and failure. Here, we use spatially resolved X-ray diffraction computed tomography to map the reaction in a composite electrode based on the LiFePO4 active material as it undergoes charge and discharge. Accelerated reactions at the electrode faces in contact with either the separator or the current collector demonstrate that both ionic and electronic transport limit the reaction progress. The data quantify how nonuniformity of the electrode reaction leads to variability in the charge/discharge rate, both as a function of time and position within the electrode architecture. Importantly, this local variation in the reaction rate means that the maximum rate that individual cathode particles experience can be substantially higher than the average, control charge/discharge rate, by a factor of at least 2-5 times. This rate heterogeneity may accelerate rate-dependent degradation pathways in regions of the composite electrode experiencing faster-than-average reaction and has important implications for understanding and optimizing rate-dependent battery performance. Benchmarking multiscale continuum model parameters against the observed reaction heterogeneity permits extension of these models to other electrode geometries.

Thermodynamic Overpotentials and Nucleation Rates for Electrodeposition on Metal Anodes.

Rechargeable batteries employing metal negative electrodes (i.e., anodes) are attractive next-generation energy storage devices because of their greater theoretical energy densities compared to intercalation-based anodes. An important consideration for a metal's viability as an anode is the efficiency with which it undergoes electrodeposition and electrodissolution. The present study assesses thermodynamic deposition/dissolution efficiencies and associated nucleation rates for seven metals (Li, Na, K, Mg, Ca, Al, and Zn) of relevance for battery applications. First-principles calculations were used to evaluate thermodynamic overpotentials at terraces and steps on several low-energy surfaces of these metals. In general, overpotentials are observed to be the smallest for plating/stripping at steps and largest at terrace sites. The difference in the coordination number for a surface atom from that in the bulk was found to correlate with the overpotential magnitude. Consequently, because of their low bulk coordination, the body-centered alkali metals (Li, Na, and K) are predicted to be among the most thermodynamically efficient for plating/stripping. In contrast, metals with larger bulk coordination such as Al, Zn, and the alkaline earths (Ca and Mg) generally exhibit higher thermodynamic overpotentials. The rate of steady-state nucleation during electrodeposition was estimated using a classical nucleation model informed by the present first-principles calculations. Nucleation rates are predicted to be several orders of magnitude larger on alkali metal surfaces than on the other metals. This multiscale model highlights the sensitivity of the nucleation behavior on the structure and composition of the electrode surface.

Self-Similarity and the Dynamics of Coarsening in Materials.

Two-phase mixtures, from metallic alloys to islands on surfaces, undergo coarsening wherein the total interfacial area of the system decreases with time. Theory predicts that during coarsening the average size-scale of a two-phase mixture increases with time as t1/3 when the two-phase mixture is self-similar, or time independent when scaled by a time-dependent length. Here, we explain why this temporal power law is so robustly observed even when the microstructure is not self-similar. We show that there exists an upper limit to the length scales in the system that are kinetically active during coarsening, which we term the self-similar length scale. Length scales smaller than the self-similar length scale evolve, leading to the classical temporal power law for the coarsening dynamics of the system. Longer length scales are largely inactive, leading to a non-self-similar structure. This result holds for any two-phase mixture with a large distribution of morphological length scales.

Localized concentration reversal of lithium during intercalation into nanoparticles.

Nanoparticulate electrodes, such as Li x FePO4, have unique advantages over their microparticulate counterparts for the applications in Li-ion batteries because of the shortened diffusion path and access to nonequilibrium routes for fast Li incorporation, thus radically boosting power density of the electrodes. However, how Li intercalation occurs locally in a single nanoparticle of such materials remains unresolved because real-time observation at such a fine scale is still lacking. We report visualization of local Li intercalation via solid-solution transformation in individual Li x FePO4 nanoparticles, enabled by probing sub-angstrom changes in the lattice spacing in situ. The real-time observation reveals inhomogeneous intercalation, accompanied with an unexpected reversal of Li concentration at the nanometer scale. The origin of the reversal phenomenon is elucidated through phase-field simulations, and it is attributed to the presence of structurally different regions that have distinct chemical potential functions. The findings from this study provide a new perspective on the local intercalation dynamics in battery electrodes.

Three-dimensional mesostructures as high-temperature growth templates, electronic cellular scaffolds, and self-propelled microrobots.

Recent work demonstrates that processes of stress release in prestrained elastomeric substrates can guide the assembly of sophisticated 3D micro/nanostructures in advanced materials. Reported application examples include soft electronic components, tunable electromagnetic and optical devices, vibrational metrology platforms, and other unusual technologies, each enabled by uniquely engineered 3D architectures. A significant disadvantage of these systems is that the elastomeric substrates, while essential to the assembly process, can impose significant engineering constraints in terms of operating temperatures and levels of dimensional stability; they also prevent the realization of 3D structures in freestanding forms. Here, we introduce concepts in interfacial photopolymerization, nonlinear mechanics, and physical transfer that bypass these limitations. The results enable 3D mesostructures in fully or partially freestanding forms, with additional capabilities in integration onto nearly any class of substrate, from planar, hard inorganic materials to textured, soft biological tissues, all via mechanisms quantitatively described by theoretical modeling. Illustrations of these ideas include their use in 3D structures as frameworks for templated growth of organized lamellae from AgCl-KCl eutectics and of atomic layers of WSe2 from vapor-phase precursors, as open-architecture electronic scaffolds for formation of dorsal root ganglion (DRG) neural networks, and as catalyst supports for propulsive systems in 3D microswimmers with geometrically controlled dynamics. Taken together, these methodologies establish a set of enabling options in 3D micro/nanomanufacturing that lie outside of the scope of existing alternatives.

Charge attachment induced transport - bulk and grain boundary diffusion of potassium in PrMnO3.

The transport of potassium through praseodymium-manganese oxide (PrMnO3; PMO) has been investigated by means of the charge attachment induced transport (CAIT) technique. To this end, potassium ions have been attached to the front side of a 250 nm thick sample of PMO. The majority of the potassium ions become neutralized at the surface of the PMO, while some of the potassium ions diffuse through. Ex situ analysis of the sample by time-of-flight secondary ion mass spectrometry (ToF-SIMS) reveals pronounced concentration profiles of the potassium, which is indicative of diffusion. Two diffusion coefficients have been obtained, namely, the bulk diffusion coefficient and the diffusion coefficient associated with the grain boundaries. The latter conclusion is supported by transmission electron microscopy of thin lamella cut out from the sample, which reveals twin grain boundaries reaching throughout the entire sample as well as model calculations.

High-Operating-Temperature Direct Ink Writing of Mesoscale Eutectic Architectures.

High-operating-temperature direct ink writing (HOT-DIW) of mesoscale architectures that are composed of eutectic silver chloride-potassium chloride. The molten ink undergoes directional solidification upon printing on a cold substrate. The lamellar spacing of the printed features can be varied between approximately 100 nm and 2 µm, enabling the manipulation of light in the visible and infrared range.

Dendrites and Pits: Untangling the Complex Behavior of Lithium Metal Anodes through Operando Video Microscopy.

Enabling ultra-high energy density rechargeable Li batteries would have widespread impact on society. However the critical challenges of Li metal anodes (most notably cycle life and safety) remain unsolved. This is attributed to the evolution of Li metal morphology during cycling, which leads to dendrite growth and surface pitting. Herein, we present a comprehensive understanding of the voltage variations observed during Li metal cycling, which is directly correlated to morphology evolution through the use of operando video microscopy. A custom-designed visualization cell was developed to enable operando synchronized observation of Li metal electrode morphology and electrochemical behavior during cycling. A mechanistic understanding of the complex behavior of these electrodes is gained through correlation with continuum-scale modeling, which provides insight into the dominant surface kinetics. This work provides a detailed explanation of (1) when dendrite nucleation occurs, (2) how those dendrites evolve as a function of time, (3) when surface pitting occurs during Li electrodissolution, (4) kinetic parameters that dictate overpotential as the electrode morphology evolves, and (5) how this understanding can be applied to evaluate electrode performance in a variety of electrolytes. The results provide detailed insight into the interplay between morphology and the dominant electrochemical processes occurring on the Li electrode surface through an improved understanding of changes in cell voltage, which represents a powerful new platform for analysis.

Electrochemical Stability Window of Imidazolium-Based Ionic Liquids as Electrolytes for Lithium Batteries.

This paper presents the computational assessment of the electrochemical stability of a series of alkyl methylimidazolium-based ionic liquids for their use as lithium battery electrolytes. The oxidation and reduction potentials of the constituent cation and anion of each ionic liquid with respect to a Li(+)/Li reference electrode were calculated using density functional theory following the method of thermodynamic cycles, and the electrochemical stability windows (ESW)s of these ionic liquids were obtained. The effect of varying the length of alkyl side chains of the methylimidazolium-based cations on the redox potentials and ESWs was investigated. The results show that the limits of the ESWs of these methylimidazolium-based ionic liquids are defined by the oxidation potential of the anions and the reduction potential of alkyl-methylimidazolium cations. Moreover, ionic liquids with [PF6](-) anion have a wider ESW. In addition to characterizing structure-function relationships, the accuracy of the computational approach was assessed through comparisons of the data against experimental measurements of ESWs. The potentials calculated by the thermodynamic cycle method are in good agreement with the experimental data while the HOMO/LUMO method overestimates the redox potentials. This work demonstrates that these approaches can provide guidance in selecting ionic liquid electrolytes when designing high-voltage rechargeable batteries.

Template-Directed Directionally Solidified 3D Mesostructured AgCl-KCl Eutectic Photonic Crystals.

3D mesostructured AgCl-KCl photonic crystals emerge from colloidal templating of eutectic solidification. Solvent removal of the KCl phase results in a mesostructured AgCl inverse opal. The 3D-template-induced confinement leads to the emergence of a complex microstructure. The 3D mesostructured eutectic photonic crystals have a large stop band ranging from the near-infrared to the visible tuned by the processing.

Model for anodic film growth on aluminum with coupled bulk transport and interfacial reactions.

Films grown through the anodic oxidation of metal substrates are promising for applications ranging from solar cells to medical devices, but the underlying mechanisms of anodic growth are not fully understood. To provide a better understanding of these mechanisms, we present a new 1D model for the anodization of aluminum. In this model, a thin space charge region at the oxide/electrolyte interface couples the bulk ionic transport and the interfacial reactions. Charge builds up in this region, which alters the surface overpotential until the reaction and bulk fluxes are equal. The model reactions at the oxide/electrolyte interface are derived from the Våland-Heusler model, with modifications to allow for deviations from stoichiometry at the interface and the saturation of adsorption sites. The rate equations and equilibrium concentrations of adsorbed species at the oxide/electrolyte interface are obtained from the reactions using Butler-Volmer kinetics, whereas transport-limited reaction kinetics are utilized at the metal/oxide interface. The ionic transport through the bulk oxide is modeled using a newly proposed cooperative transport process, the counter-site defect mechanism. The model equations are evolved numerically. The model is parametrized and validated using experimental data in the literature for the rate of ejection of aluminum species into the electrolyte, embedded charge at the oxide/electrolyte interface, and the barrier thickness and growth rate of porous films. The parametrized model predicts that the embedded charge at the oxide/electrolyte interface decreases monotonically for increasing electrolyte pH at constant current density. The parametrized model also predicts that the embedded charge during potentiostatic anodization is at its steady-state value; the embedded charge at any given time is equal to the embedded charge during galvanostatic anodization at the same current. In addition to simulations of anodized barrier films, this model can be extended to multiple dimensions to simulate anodic nanostructure growth.

Tracking lithium transport and electrochemical reactions in nanoparticles.

Expectations for the next generation of lithium batteries include greater energy and power densities along with a substantial increase in both calendar and cycle life. Developing new materials to meet these goals requires a better understanding of how electrodes function by tracking physical and chemical changes of active components in a working electrode. Here we develop a new, simple in-situ electrochemical cell for the transmission electron microscope and use it to track lithium transport and conversion in FeF(2) nanoparticles by nanoscale imaging, diffraction and spectroscopy. In this system, lithium conversion is initiated at the surface, sweeping rapidly across the FeF(2) particles, followed by a gradual phase transformation in the bulk, resulting in 1-3 nm iron crystallites mixed with amorphous LiF. The real-time imaging reveals a surprisingly fast conversion process in individual particles (complete in a few minutes), with a morphological evolution resembling spinodal decomposition. This work provides new insights into the inter- and intra-particle lithium transport and kinetics of lithium conversion reactions, and may help to pave the way to develop high-energy conversion electrodes for lithium-ion batteries.