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<p>Aluminum foil anodes offer high theoretical capacity for lithium-ion batteries but are limited by mechanical degradation, resistive SEI formation, and poor cycling stability. Commercial Al foil, produced via direct chill casting and extensive rolling, contains coarse grains that lead to non-uniform lithiation and increased fracture susceptibility. This study investigates vertical twin-roll casting (VTRC) as an alternative processing route to refine grain structure and enhance electrochemical performance. VTRC_Al foil (50&#xa0;µm thick) exhibited lower SEI resistance, reduced LiF accumulation, and improved lithium-ion transport, maintaining a capacity of 2.5&#xa0;mAh/cm<sup>2</sup> over 85 cycles, whereas commercial foil degraded after 34 cycles. SEM analysis showed that commercial foil developed surface cracks, while VTRC_Al foil retained structural integrity, mitigating capacity fade. Pole figure analysis confirmed the presence of cubic texture in both foils, indicating that grain size, rather than texture, plays a dominant role in electrochemical performance. These findings highlight VTRC as a promising method for producing Al foil anodes with improved stability, suggesting that further optimization of processing parameters and alloying strategies could enhance cycle life and initial coulombic efficiency.</p> Graphical Abstract <p></p>

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Vertically Twin-Roll Casted Aluminum Foil Anode for Lithium-ion Batteries

  • 期刊论文

  • 发表日期：

    2025年6月10日

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  • Ashwani Pandey,
  • Somen Jena,
  • R. Sabat,
  • Animesh Mandal,
  • S. Pati

摘要

Aluminum foil anodes offer high theoretical capacity for lithium-ion batteries but are limited by mechanical degradation, resistive SEI formation, and poor cycling stability. Commercial Al foil, produced via direct chill casting and extensive rolling, contains coarse grains that lead to non-uniform lithiation and increased fracture susceptibility. This study investigates vertical twin-roll casting (VTRC) as an alternative processing route to refine grain structure and enhance electrochemical performance. VTRC_Al foil (50 µm thick) exhibited lower SEI resistance, reduced LiF accumulation, and improved lithium-ion transport, maintaining a capacity of 2.5 mAh/cm2 over 85 cycles, whereas commercial foil degraded after 34 cycles. SEM analysis showed that commercial foil developed surface cracks, while VTRC_Al foil retained structural integrity, mitigating capacity fade. Pole figure analysis confirmed the presence of cubic texture in both foils, indicating that grain size, rather than texture, plays a dominant role in electrochemical performance. These findings highlight VTRC as a promising method for producing Al foil anodes with improved stability, suggesting that further optimization of processing parameters and alloying strategies could enhance cycle life and initial coulombic efficiency.

Graphical Abstract