PDF

Thermal Spray as a Scalable Alternative Processing Route for Solid-State Thin-Film Batteries

Ameey Anupam, Shrikant Joshi

2025enthermal spraybatteriesmanufacturingcoatingsenergy

Abstract

Language:

Solid-state thin-film batteries (SSTFBs) are attractive for applications where small footprint, safety, long cycle life, and device integration are more important than high absolute capacity. Their fabrication presently remains strongly tied to vacuum-based methods, which provide dense layers but have limitations such as low deposition rates and high costs. This review assesses whether thermal spray approaches can be useful for SSTFB manufacture by examining the characteristics of thermal spraying in relation to battery layer requirements. The discussion summarizes SSTFB materials and conventional processing constraints, focusing on the suitability of thermal spraying based on thermal exposure, kinetic energy, and phase retention. Compatibility is explored for SSTFB anodes, cathodes, solid electrolytes, and current collectors. Recent studies show thermally sprayed constituents can possess electrochemical functionality; however, challenges including ion loss, phase formation, and reproducibility persist. Despite these issues, the review suggests a promising near-term role for thermal spray in fabricating layers and current collectors, with potential for hybrid architectures that synergize with traditional thin-film methods to optimize performance quality.

Download

Cite This Work

@article{b7ada471-79f8-4816-bf4e-26ea5b33d90c,
  title={Thermal Spray as a Scalable Alternative Processing Route for Solid-State Thin-Film Batteries},
  author={Ameey Anupam and Shrikant Joshi},
  year={2025},
  language={en}
}
TY  - JOUR
TI  - Thermal Spray as a Scalable Alternative Processing Route for Solid-State Thin-Film Batteries
AU  - Ameey Anupam
AU  - Shrikant Joshi
PY  - 2025
LA  - en
ER  -

Similar Items

Metal Casting Processes

Unknown, Unknown

This chapter discusses metal casting processes, highlighting the diversity and common characteristics among them. The objective is to elucidate the fu

2023enPDF

Coordinated supply scheduling of offshore and onshore hydrogen considering power and transportation networks

Xiong Wu, Yu Zhang

Converting offshore wind energy into hydrogen is a promising approach to improving renewable energy utilization. Coordinated offshore and onshore oper

2027enPDF

Bridging the climate to energy data gap: simulated annealing for representative climate year selection

Bram van Duinen, Karin van der Wiel

Energy system models are increasingly dependent on representative climate input. Yet, a fundamental mismatch persists between the hundreds of simulate

2026enPDF

640069

Roger Rumbu

2025enPPTX

Tariffs, energy contracts, and optimal Distributed Energy Resources investment in campus microgrids

Juan Manuel Alemany, Bruno Bignotti

Large institutional electricity consumers such as university campuses face a planning problem that cannot be reduced to photovoltaic sizing alone. The

2026esPDF

Artificial intelligence-aided materials design: AI-algorithms and case studies on alloys and metallurgical processes

Rajesh Jha, Bimal Kumar Jha

This book describes the application of artificial intelligence (AI) and machine learning (ML) concepts to develop predictive models that can be used t

2022enPDF