Understanding the relationships between porous transport layer (PTL) morphology and oxygen removal is essential to improve the polymer electrolyte water electrolyzer (PEWE) performance. Operando X-ray computed tomography and machine learning were performed on a model electrolyzer at different water flow rates and current densities to determine how these operating conditions alter oxygen transport in the PTLs. We report a direct observation of oxygen taking preferential pathways through the PTL, regardless of the water flow rate or current density (1-4 A/cm2). Oxygen distribution in the PTL had a periodic behavior with period of 400 μm. A computational fluid dynamics model was used to predict oxygen distribution in the PTL showing periodic oxygen front. Observed oxygen distribution is due to low in-plane PTL tortuosity and high porosity enabling merging of oxygen bubbles in the middle of the PTL and also due to aerophobicity of the layer.

Replacing the conventional graphite anode in rechargeable batteries with lithium metal results in a significant increase in energy density. However, growth of electronically conductive structures, like dendrites, from lithium anodes causes premature battery failure by short circuit. Mechanically rigid electrolytes are thought to promote smooth lithium deposition by increasing the energy required for lithium reduction at regions of high local strain, like a dendrite tip. The study reported herein used X-ray microtomography, Focused Ion Beam (FIB) milling, and Scanning Electron Microscopy (SEM) imaging to investigate the electrochemical stripping and deposition behavior of lithium in symmetric lithium – polymer cells using a rigid polystyrene-b-poly(ethylene oxide) membrane as the electrolyte. In situ experiments show the formation of globular lithium structures that grow to puncture the polymer electrolyte membrane. They form on faceted impurity particles that are initially located at the lithium/electrolyte interface. While the impurities are uniformly distributed throughout the lithium foil in initial images, their relative concentration near the electrolyte changes as lithium is stripped from one electrode and deposited on the other. Notably, the deposited lithium is devoid of faceted impurities. This electrolytic refining of lithium could be used to prepare anodic lithium foils for batteries with improved cycle life.

All solid-state lithium batteries are, potentially, higher energy density and safer alternatives to conventional lithium-ion batteries (LIBs). These are particularly attractive characteristics for large-scale applications such as electric vehicles and grid energy storage systems. However, the thin film deposition techniques used to make current devices are not readily scalable, and result in low areal capacities, which translate to low practical energy densities. To overcome these deficiencies, it is necessary to design thicker electrodes similar to what are used in LIBs (30–100 μm), in which the active material is composited with an ionic conductor and an electronically conducting additive, to overcome transport limitations. In this paper, we propose a method for making such an electrode, starting with a porous scaffold, i.e. Li₇La₃Zr₂O₁₂ (LLZO), made by freeze casting, which is then infiltrated with the active material LiNi_0.6Mn_0.2Co_0.2O₂ (NMC-622) and other components. The freeze casting technique results in the formation of oriented channels with low tortuosity, which run roughly parallel to the direction of the current. The scaffolds were characterized with synchrotron X-ray micro-tomography for structural analysis, as well as synchrotron X-ray fluorescence to map the elemental distribution in the infiltrated composite. A hybrid half-cell was constructed and cycled as proof of principle, and it showed good stability. In addition, a bilayer structure consisting of a porous layer combined with a dense LLZO film was successfully made as a prototype of an all solid-state battery. A mathematical model was established to propose optimized scaffold structures for battery performance.