Recent advances in synthesis and fabrication of LiFePO4 cathode materials: a comprehensive review

Lithium iron phosphate (LiFePO₄/LFP) batteries have great potential to significantly impact the electric vehicle market. These batteries are synthesized using lithium, iron, and phosphate as precursors. They offer several advantages, such as abundant availability, low toxicity, high thermal stability, and cost-effectiveness, making them an attractive option for electric vehicle applications. However, the widespread adoption of LFP batteries faces several challenges, including the limited availability of suitable precursors and the need for a more optimized fabrication process to ensure consistent and efficient performance. Therefore, a thorough understanding of the LFP battery fabrication process is essential. This paper aims to comprehensively understand the synthesis routes and suitability of various iron sources for LFP battery production. These synthesis processes include various synthesis methods such as hydrothermal, spray pyrolysis, sol-gel, solid-state, dry emulsion, microwave heating, carbothermal, mechanochemical activation, and coprecipitation. Each method offers specific advantages and disadvantages regarding efficiency, quality of the resulting material, and compatibility with the available iron source. By exploring and optimizing appropriate fabrication methods, we can overcome the key challenges hindering the development of LFP batteries, increase their capacity and cycle life, and accelerate their adoption in the global electric vehicle market.