Controlled Dy-doping to nickel-rich cathode materials in high temperature aerosol synthesis

Layered nickel-rich materials are promising next-generation cathode materials for lithium ion batteries due to their high capacity and low cost. However, the poor thermal stability and longtime cycling performance hinders the commercial applications of high nickel materials. Doping with heteroatoms has been an effective approach for improving electrochemical performance of cathode materials. Controlling doping concentration and geometrical distribution is desired for optimal electrochemical performance, but it is challenging in traditional co-precipitation methods. In this study, controlled dysprosium (Dy) doping to NCM811 was investigated in an aerosol synthesis method by controlling the precursor concentrations and heating parameters. The obtained materials were characterized by SEM, XRD, and XPS, and their electrochemical properties and thermal stability were evaluated. By controlling the doping concentration (1.5%), Dy-doped NCM811 was improved simultaneously in long-term cycling and high-rate performance. The thermal-chemical stability of the Dy-doped cathode materials was examined in a microflow reactor with a mass spectrometer. Results showed that Dy-doping shifted the O₂ onset temperature to a higher temperature and reduced O₂ release by 80%, thus dramatically increasing the thermal-chemical stability and improving the fire safety of these cathode materials. This study successfully demonstrated the great strength of the high temperature aerosol synthesis approach for controlling ion doping, which enables the improvement of high nickel materials systematically in different aspects. Since high temperature aerosol synthesis is a low-cost and scalable method, the findings in this work have broad implications for commercial synthesis of novel materials with controlled doping modification to achieve high electrochemical performance and safety in lithium ion batteries.