Fabricate novel anode based on Si alloy for Li-ion battery using cold spray technique

A Si-based alloy anode for rechargeable Li-ion batteries will be created using “cold spray”, a solid-state materials deposition technique. In this process inert driver gas is used to accelerate powdered feedstock particles to supersonic speeds. No melting occurs, instead deposits form as a result of severe deformation. This allows deposition of Si, a material prone to oxidation otherwise. Initial Phase I results showed that Si-based alloys were successfully deposited with minimal (<5%) oxygen update. These anodes will allow for much higher capacity Li-ion batteries without needing to change anything else in current batteries. This will enable quick uptake in the commercial market, and the first manufacturer of this technology will have a substantial competitive advantage in the growing rechargeable battery market, which is expected to attract $620 billion in investments over the next two decades. With this anode, electric cars with ranges of 1000 miles will be possible, along with longer-lasting consumer electronic batteries, increased endurance of Dept. of Defense assets, and increased operating time of on-the-ground warfighters and search-and-rescue personnel.