{"title":"Interplays between preparation and processing of the catalyst ink in the manufacturing of a proton exchange membrane fuel cell catalyst layer","authors":"Jackie Burghart , Guillaume Ovarlez, Yaocihuatl Medina-Gonzalez","doi":"10.1016/j.jpowsour.2025.238497","DOIUrl":"10.1016/j.jpowsour.2025.238497","url":null,"abstract":"<div><div>Catalyst inks are essential for the fabrication of Catalyst Layers (CLs) in Proton Exchange Membrane Fuel Cell (PEMFC) electrodes. While the fabrication process appears straightforward and numerous innovations have emerged in both research and industry, a comprehensive and openly accessible framework for rational ink formulation and CL fabrication is still developing. This gap is largely due to limited public insight into the links between ink and CL properties, structure, and performance, as much industrial know-how remains proprietary. This paper first examines the preparation of catalyst inks—primarily composed of an ionomer, catalyst, solvent, and sometimes additives such as antioxidants—highlighting recent advances in understanding their properties, interactions and influence on ink behaviour and processability. The discussion then turns to ink coating techniques, such as spraying and printing, and explores how these methods impact the structural, mechanical, and chemical characteristics of the resulting CL. Drying processes are also considered, with attention to how different approaches affect final CL properties. By analysing the interplay between ink formulation, coating, and drying, this work sheds light on the feedback-driven, iterative dynamics that underpin CL fabrication in PEMFCs, aiming to guide more rational and effective design strategies.</div></div>","PeriodicalId":377,"journal":{"name":"Journal of Power Sources","volume":"660 ","pages":"Article 238497"},"PeriodicalIF":7.9,"publicationDate":"2025-10-15","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145326289","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Yijing Shang , Yuliang Liu , Xiufu Sun , Julian Taubmann , Peter Stanley Jørgensen , Henrik Lund Frandsen , Ming Chen
{"title":"Exploration of the relationship between operation conditions and microstructure degradation of Ni/YSZ electrodes in solid oxide electrolysis cells","authors":"Yijing Shang , Yuliang Liu , Xiufu Sun , Julian Taubmann , Peter Stanley Jørgensen , Henrik Lund Frandsen , Ming Chen","doi":"10.1016/j.jpowsour.2025.238577","DOIUrl":"10.1016/j.jpowsour.2025.238577","url":null,"abstract":"<div><div>Solid oxide electrolysis cells (SOEC) play an important role in the advancement of sustainable energy technologies, enabling efficient conversion of green electricity into chemical energy through electrolysis processes. However, the SOEC performance degradation mainly due to nickel migration in the Ni/yttria stabilized zirconia (YSZ) fuel electrode, poses a significant challenge to the widespread application and commercialization of the SOEC technology. In addition, the precise mechanisms behind the observed microstructural degradation are so far not fully understood and require further investigation. In this work, the microstructure evolution of Ni/YSZ electrodes after long-term operation in an H<sub>2</sub>O/H<sub>2</sub> atmosphere at 800 °C is investigated using 2D SEM analysis and 3D reconstruction. The effect of variation in local current density and operation duration on Ni migration is explored. The inhomogeneity in the fuel electrode microstructure degradation along the gas flow direction is also examined. Furthermore, the influence of the fuel electrode overpotential and the operation duration on Ni migration is investigated based on the results from this work and previous research. Finally, a relationship between microstructural degradation and local and global operating conditions is proposed. The proposed correlation seems to fit the experimental data well. This makes it possible to predict the extent of Ni migration through operational conditions with more experimental verification in the future.</div></div>","PeriodicalId":377,"journal":{"name":"Journal of Power Sources","volume":"661 ","pages":"Article 238577"},"PeriodicalIF":7.9,"publicationDate":"2025-10-15","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145322674","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Longfei Han , Mengdan Zhang , Xiangming Hu , Jinfeng Li , Xinyue Yang , Lihua Jiang , Yurui Deng , Yuan Cheng , Zhenglong He , Biao Kong
{"title":"Multi-parameter thermal runaway monitoring platform unraveling SOC-dependent thermal runaway mechanisms in LiNi0.8Co0.1Mn0.1O2 batteries","authors":"Longfei Han , Mengdan Zhang , Xiangming Hu , Jinfeng Li , Xinyue Yang , Lihua Jiang , Yurui Deng , Yuan Cheng , Zhenglong He , Biao Kong","doi":"10.1016/j.jpowsour.2025.238594","DOIUrl":"10.1016/j.jpowsour.2025.238594","url":null,"abstract":"<div><div>Thermal runaway (TR) propagation in lithium-ion batteries, particularly in high-nickel LiNi<sub>0.8</sub>Co<sub>0.1</sub>Mn<sub>0.1</sub>O<sub>2</sub> (NCM811) batteries, poses critical safety concerns for energy storage system. The state of charge (SOC) is a critical factor influencing battery safety. This study systematically investigates TR behaviors in 18650-type NCM811 batteries under 0%, 50%, and 100% SOC conditions using an integrated multi-parameter monitoring platform. The platform combines programmable thermal stimulation, synchronized thermocouple arrays, infrared imaging (capturing spatial-temporal temperature gradients), and cone calorimetry (quantifying heat and smoke release rates). Results reveal a strong SOC-dependent TR response: Fully charged batteries (100% SOC) show a 73.9% increase in total heat release (16.1 MJ/m<sup>2</sup> vs. 4.2 MJ/m<sup>2</sup> at 50% SOC) and accelerated CO/CO<sub>2</sub> emissions due to intensified electrolyte decomposition. Paradoxically, fully discharged batteries (0% SOC) produce higher cumulative smoke, which is attributed to incomplete oxidation of carbonaceous anode materials under moderated TR conditions. These quantitative correlations help resolve conflicting combustion behaviors across SOC levels and provide mechanistic insights for SOC-specific thermal management strategies in battery safety design. The novel TR testing platform enables comprehensive analysis of battery failure progression and supports in-depth investigations into lithium-ion battery safety enhancement.</div></div>","PeriodicalId":377,"journal":{"name":"Journal of Power Sources","volume":"661 ","pages":"Article 238594"},"PeriodicalIF":7.9,"publicationDate":"2025-10-14","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145324022","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
DoEun Kim , Taeyang Han , JunYoung Seo , HangJin Jo
{"title":"Effective water management through microporous-layer wettability control for high power density in low-temperature fuel cells","authors":"DoEun Kim , Taeyang Han , JunYoung Seo , HangJin Jo","doi":"10.1016/j.jpowsour.2025.238524","DOIUrl":"10.1016/j.jpowsour.2025.238524","url":null,"abstract":"<div><div>Water management in microporous layers (MPLs) is a major challenge in low-temperature fuel cells. This study introduces a simple method to fabricate a biphilic MPL with in-plane hydrophilic and hydrophobic regions. The hydrophilic ratio is systematically controlled to analyze its effect on cell performance. Surface wettability is selectively modified via plasma treatment and subsequent NaOH treatment, while preserving the original structure. Contact-angle measurements and energy-dispersive X-ray spectroscopy confirm successful modification. Among the tested configurations, a hydrophilic ratio of 25.0 % exhibits the most favorable performance among the tested conditions: a 28.8 % increase in current density at 0.6 V and 22.2 % increase in maximum power density relative to the hydrophobic MPL. Electrochemical impedance spectroscopy reveals improved mass transfer in the biphilic structure. A 5-h water-drainage test confirms its superior water-removal capability. Comparative analysis with previous studies employing similar surface modification techniques further demonstrates enhanced performance of the proposed MPL, which exhibits the largest improvement in current density at 0.6 V among reported results. These findings indicate that in-plane wettability patterning promotes liquid–gas pathway separation. The proposed method is simple, scalable, and applicable for improving liquid–gas management and performance in low-temperature fuel cells.</div></div>","PeriodicalId":377,"journal":{"name":"Journal of Power Sources","volume":"660 ","pages":"Article 238524"},"PeriodicalIF":7.9,"publicationDate":"2025-10-14","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145326290","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Wooseok Go , Dilworth Y. Parkinson , Elizabeth Clark , Marca M. Doeff , Michael C. Tucker
{"title":"Developing cathode infiltration processes for all-solid-state bilayer LLZO cells","authors":"Wooseok Go , Dilworth Y. Parkinson , Elizabeth Clark , Marca M. Doeff , Michael C. Tucker","doi":"10.1016/j.jpowsour.2025.238595","DOIUrl":"10.1016/j.jpowsour.2025.238595","url":null,"abstract":"<div><div>To realize the bilayer architecture of lithium lanthanum zirconate (LLZO) for application in solid-state batteries (SSBs), the scaffold structure must be optimized, and effective cathode infiltration strategies must be established. In this study, we fabricate a modified bilayer LLZO using a sacrificial layer to enhance surface porosity, and systematically investigate various cathode infiltration techniques to fill the scaffold with oxide cathode active materials (CAM). Structural characterizations showed that the sacrificial layer significantly increased open surface porosity, enabling the surface of the scaffold to be filled with CAM. To further increase infiltration depth, applying vacuum or vibration was compared, with the full-depth infiltration achieved using a sonicator-based vibration. Full cells prepared using the modified bilayer LLZO and vibration-assisted technique demonstrated successful operation. This work demonstrates a practical and scalable approach for engineering bilayer LLZO structures and integrating oxide cathodes into porous scaffolds, offering a promising pathway toward high-performance solid-state batteries.</div></div>","PeriodicalId":377,"journal":{"name":"Journal of Power Sources","volume":"661 ","pages":"Article 238595"},"PeriodicalIF":7.9,"publicationDate":"2025-10-14","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145323341","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Kundan Singh Rawat , Chetna Tewari , Tanuja Arya , Prabhat Pant , Young Nam Kim , Raj Kumar , Yong Chae Jung , Nanda Gopal Sahoo
{"title":"Sustainable conversion of waste plastic into reduced graphene oxide for superior supercapacitor applications: A comparative electrolyte study","authors":"Kundan Singh Rawat , Chetna Tewari , Tanuja Arya , Prabhat Pant , Young Nam Kim , Raj Kumar , Yong Chae Jung , Nanda Gopal Sahoo","doi":"10.1016/j.jpowsour.2025.238601","DOIUrl":"10.1016/j.jpowsour.2025.238601","url":null,"abstract":"<div><div>The present study investigates the upcycling of waste polyethylene (PE) and polyethylene terephthalate (PET) into reduced graphene oxide (rGO) through a nanoclay-assisted melt mixing and pyrolysis process. A comparative electrochemical evaluation is performed using sulfuric acid (H<sub>2</sub>SO<sub>4</sub>), potassium hydroxide (KOH), and potassium chloride (KCl), electrolytes in a three-electrode configuration. The rGO derived from PE with 0.5 wt% nanoclay catalyst (PE_0.5-rGO) exhibits as the best performer, achieving a specific capacitance of 482.9 F/g at 0.5 A/g in 1 M H<sub>2</sub>SO<sub>4</sub>. Further testing in a two-electrode system reveals enhanced capacitance and excellent cyclic stability, underscoring the potential for practical applications. The fabricated device executes a maximum energy density of 53.5 Wh/kg at a power density of 280 W/kg. Additionally, this device shows remarkable long-term cycling stability, retaining approximately 83.1 % of its initial capacitance after 12,000 charge-discharge cycles. These findings demonstrate an efficient route for converting plastic waste into high-performance supercapacitor materials.</div></div>","PeriodicalId":377,"journal":{"name":"Journal of Power Sources","volume":"661 ","pages":"Article 238601"},"PeriodicalIF":7.9,"publicationDate":"2025-10-14","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145322671","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Zhi-Hui Wu , Peng Song , Xiao-Hong Zheng , Xiao-Juan Ye , Chun-Sheng Liu
{"title":"Non-hexagonal tetra-hexa-octa-graphene for high-performance sodium-ion battery anodes: Effects of structural topology, mechanical strain, and van der Waals coupling","authors":"Zhi-Hui Wu , Peng Song , Xiao-Hong Zheng , Xiao-Juan Ye , Chun-Sheng Liu","doi":"10.1016/j.jpowsour.2025.238598","DOIUrl":"10.1016/j.jpowsour.2025.238598","url":null,"abstract":"<div><div>Although numerous freestanding monolayer carbon allotropes have been proposed as anode candidates for sodium-ion batteries (SIBs), the influence of substrate-induced lattice strain and interfacial van der Waals interactions on their electrochemical performance remains largely unexplored. Using first-principles calculations, we predict a carbon allotrope, THO-graphene, composed of tetra-, hexa-, and octa-carbon rings, which exhibits an indirect bandgap semiconducting behavior. Monolayer THO-graphene demonstrates a high Na storage capacity (1340.05 mAh g<sup>−1</sup>), a low diffusion barrier (0.35 eV), and a low average open-circuit voltage (0.12 V), highlighting its potential as an anode material for SIBs. Remarkably, uniaxial strain ranging from −6 % to 6 % triggers a semiconductor-to-metal transition in THO-graphene, boosting its electrical conductivity while introducing anisotropic Na adsorption characteristics and reducing the diffusion barrier to an ultralow value of 0.14 eV. Furthermore, the inherently metallic bilayer THO-graphene enhances Na adsorption capability and preserves rapid diffusion kinetics.</div></div>","PeriodicalId":377,"journal":{"name":"Journal of Power Sources","volume":"661 ","pages":"Article 238598"},"PeriodicalIF":7.9,"publicationDate":"2025-10-14","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145323339","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Wei Chen, Guanghua Guo, Zichuan Huai, Bin Liu, Hongtao Lan
{"title":"Dynamic modeling and control strategy optimization of photovoltaic-electrolyzer system via equivalent dynamic impedance","authors":"Wei Chen, Guanghua Guo, Zichuan Huai, Bin Liu, Hongtao Lan","doi":"10.1016/j.jpowsour.2025.238554","DOIUrl":"10.1016/j.jpowsour.2025.238554","url":null,"abstract":"<div><div>To address the dynamic mismatch between photovoltaic (PV) generation and alkaline water electrolysis in green hydrogen production systems, this study proposes an integrated dynamic modeling framework incorporating equivalent dynamic impedance. A nonlinear model comprising a PV array, DC–DC converter, and alkaline electrolyzer is established, elucidating how impedance matching governs electrolyzer performance under solar irradiance fluctuations. Real-time current–voltage feedback enables accurate characterization of the dynamic response within the 0.1–0.4 A/cm<sup>2</sup> range. Genetic algorithm optimization yields an optimal configuration: proportional gain = 14.93; integral gain = 1.97; 29.77 wt% KOH concentration; and 368.14 K operating temperature, achieving 82.67 % system efficiency. The equivalent dynamic impedance model, combined with an improved adaptive step-size P&O algorithm, reduces dynamic response time to below 10 ms and energy efficiency fluctuation error to 1.1 % (versus 3.2 % under static impedance). Simulations demonstrate superior hydrogen production rate tracking under cloudy conditions compared to conventional methods. This work provides a novel theoretical foundation for real-time control of PV-electrolyzer systems, enhancing stability for practical deployment.</div></div>","PeriodicalId":377,"journal":{"name":"Journal of Power Sources","volume":"660 ","pages":"Article 238554"},"PeriodicalIF":7.9,"publicationDate":"2025-10-14","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145326288","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
{"title":"Cellulose-based all-in-one supercapacitor with robust interfaces and mechanical stability","authors":"Jiayi Zhang , Xinyue Cheng , Shiqin Liao , Qingqing Wang , Qufu Wei","doi":"10.1016/j.jpowsour.2025.238607","DOIUrl":"10.1016/j.jpowsour.2025.238607","url":null,"abstract":"<div><div>The unstable electrode-electrolyte interfaces of flexible supercapacitors hinder their further development as the energy supply for wearable electronic devices. Herein, reduced graphene oxide/cobalt nickel double hydroxide nanocomposites (marked as rGO/CoNi-LDH) with a stable multi-level nanosheet structure are synthesized through template etching. Benefiting from the synergistic effect of rGO with highly conductive network and CoNi-LDH with high theoretical specific capacitance, the rGO/CoNi-LDH nanocomposites demonstrate excellent specific capacitance and outstanding cycling stability. Subsequently, the composite flexible electrodes (marked as BC/CNTs/RL) composed of bacterial cellulose (BC, enhances mechanical flexibility), carbon nanotubes (CNTs, improves conductivity), and rGO/CoNi-LDH (marked as RL) are constructed. Notably, the assembled symmetrical supercapacitors (SSCs) with BC/CNTs/RL as electrodes present areal capacitance of 630.7 mF cm<sup>−2</sup> and significant area energy density (0.17 mWh cm<sup>−2</sup> at 5 mA cm<sup>−2</sup>). On this basis, the solid-state all-in-one SSCs are assembled by continuous vacuum filtration process, which demonstrate excellent interface stability (84.8 % capacitance retention after 1000 bending deformations) and electrochemical output stability (92.5 % capacitance retention under 3D winding). This research provides ideas for enhancing the performance of nanomaterials, rapidly and conveniently constructing all-in-one supercapacitors with robust interfaces.</div></div>","PeriodicalId":377,"journal":{"name":"Journal of Power Sources","volume":"661 ","pages":"Article 238607"},"PeriodicalIF":7.9,"publicationDate":"2025-10-14","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145322661","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Qi Zhang , Cong Zhang , Dafang Wang , Ziwei Hao , Shiqin Chen , Bingbing Hu , Xuan Liang
{"title":"Non-iterative parameter identification for lithium-ion battery kinetics across multiple frequency ranges via electrochemical impedance model","authors":"Qi Zhang , Cong Zhang , Dafang Wang , Ziwei Hao , Shiqin Chen , Bingbing Hu , Xuan Liang","doi":"10.1016/j.jpowsour.2025.238533","DOIUrl":"10.1016/j.jpowsour.2025.238533","url":null,"abstract":"<div><div>Accurate and efficient parameter identification is essential for lithium-ion battery management and detection applications, as it enables precise state estimation, fault diagnosis, and quality assessment. However, conventional iterative identification methods suffer from long computation times, while deep learning-based approaches require extensive training, making them impractical for applications demanding rapid and real-time parameter acquisition. To address these challenges, this paper proposes a novel EIS-based non-iterative parameter identification method, which directly maps kinetic parameters to impedance characteristics using a simplified electrochemical impedance model. By eliminating iterative calculations and training overhead, the proposed method significantly improves identification speed while maintaining high accuracy. Experimental results show that it achieves a relative mean absolute error below 1 % and 6 % for negative and positive electrode impedance simulations, respectively. Furthermore, parameter consistency is validated by applying the identified parameters to time-domain electrochemical model simulations, yielding a root mean square error of 1.63 mV under high-frequency custom pulse conditions and 34.07 mV under dynamic stress test conditions. These results demonstrate the method's strong potential for real-time battery state estimation and efficient parameter identification in battery management systems, as well as rapid quality assessment in production lines.</div></div>","PeriodicalId":377,"journal":{"name":"Journal of Power Sources","volume":"661 ","pages":"Article 238533"},"PeriodicalIF":7.9,"publicationDate":"2025-10-14","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145323284","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}