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<p>This study investigates the influence of stand-off distance (SOD) on the microstructure and electrochemical performance of LiCoO<sub>2</sub> (LCO) cathodes fabricated by atmospheric plasma spraying (APS). Granulated LCO powders were deposited at SODs of 6-14&#xa0;cm and subsequently annealed at 600&#xa0;°C. Shorter SODs enhanced particle melting, interlamellar bonding, and coating densification, while excessively short distances (≤6&#xa0;cm) caused substrate overheating and delamination. The optimized condition of 8&#xa0;cm produced a dense, defect-minimized 45-μm coating using 20 spray passes. After annealing, the cathode exhibited improved crystallinity and strengthened (101)/(104) texture, facilitating Li<sup>+</sup> transport and reducing internal resistance. The optimized APS-LCO film delivered a high specific capacity of 131.2 mAh g<sup>−1</sup> at 0.1 C and retained 93.7% capacity after 50 cycles. The resultant areal capacity (2.2 mAh cm<sup>−2</sup>) meets practical solid-state battery requirements and surpasses the thickness limits of vacuum-based deposition methods. These results highlight APS as a scalable, high-throughput technique for producing thick, binder-free LCO cathodes with promising structural and electrochemical characteristics.</p>

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Effect of Spray Distance on the Microstructure and Electrochemical Performance of LiCoO2 Cathodes Fabricated by Atmospheric Plasma Spraying

  • 期刊论文

  • 发表日期：

    2026年3月3日

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  • C. H. Yang,
  • C. H. Tsai,
  • C. L. Chang

摘要

This study investigates the influence of stand-off distance (SOD) on the microstructure and electrochemical performance of LiCoO2 (LCO) cathodes fabricated by atmospheric plasma spraying (APS). Granulated LCO powders were deposited at SODs of 6-14 cm and subsequently annealed at 600 °C. Shorter SODs enhanced particle melting, interlamellar bonding, and coating densification, while excessively short distances (≤6 cm) caused substrate overheating and delamination. The optimized condition of 8 cm produced a dense, defect-minimized 45-μm coating using 20 spray passes. After annealing, the cathode exhibited improved crystallinity and strengthened (101)/(104) texture, facilitating Li+ transport and reducing internal resistance. The optimized APS-LCO film delivered a high specific capacity of 131.2 mAh g−1 at 0.1 C and retained 93.7% capacity after 50 cycles. The resultant areal capacity (2.2 mAh cm−2) meets practical solid-state battery requirements and surpasses the thickness limits of vacuum-based deposition methods. These results highlight APS as a scalable, high-throughput technique for producing thick, binder-free LCO cathodes with promising structural and electrochemical characteristics.