Abstract
Significant amount of research has been done recently on how to increase energy densities while maintaining or lowering costs in response to the growing demand for lithium-ion batteries (LIBs). In order to achieve optimization of the manufacturing process of batteries, it is essential to understand the influence of each process stage on the architectures of the electrodes, which affects the energy, power, lifetime and safety of the LIB cells. Our ERC-funded ARTISTIC project 1 develops a digital twin that enables predicting the electrode architectures and their electrochemical performances from parameters at each stage of the LIBs manufacturing process. In this work, we present our most recent research, which studies the manufacturing process of LiNi x Mn y Co 1-x-y O 2 (NMC)-based cathodes and especially focuses on the electrode calendering stage 2 . Our methodology encompasses coarse-grained molecular dynamics and discrete element method to simulate the calendering process of electrodes that are virtually produced after the drying and slurry simulations. In this new work, we account in our model for non-spherical NMC secondary particles with realistic 3D shapes derived by X-ray computed tomography (XCT), together with spherical particles representing the carbon binder domain. An in situ compressing micro-XCT experiment is carried out on the NMC electrode to monitor the change of the electrode morphology upon the calendering process. The findings from the simulation are validated by comparing our predicted electrode architectures with the experimental ones. Our approach captures the alterations in orientation of the secondary particles throughout the calendering processes and the relaxation process, as well as their possible deformation and spring back effect brought on by the pressure. Additionally, we discuss the comparison of variations in porosity, tortuosity factor, conductivity, different phases distribution and pore size distribution during the calendering process. ERC Artistic : Home Artistic. http://www.erc-artistic.eu/. Xu, J., Ngandjong, A.C., Liu, C., Zanotto, F.M., Arcelus, O., Demortière, A., and Franco, A.A. (2023). Lithium ion battery electrode manufacturing model accounting for 3D realistic shapes of active material particles. Journal of Power Sources 554 , 232294. 10.1016/j.jpowsour.2022.232294.