The nature abundant sodium metal is proposed as ideal anode materials for advanced batteries due to its high specific capacity of 1166mAh g-1 and low redox potential of -2.71V. However, the uncontrollable dendritic Na formation and low coulombic efficiency are still major obstacles for applications. Notably, the unstable and inhomogeneous solid electrolyte interphase (SEI) is recognized to be the root cause. As SEI layer plays a critical role in regulating uniform Na deposition and improving cycling stability, researches on SEI modification, especially the artificial SEI modifications has been extensively investigated recently. In this regard, we discussed the advances on artificial interface engineering from the aspects of inorganic, organic and hybrid inorganic/organic protective layers. Finally, we also highlighted the conclusions and key prospects for further investigations. We hope this review can provide a new insight for sodium metal protection.

Sodium-potassium (NaK) liquid alloy is a promising candidate for use as anode material in sodium batteries because of its fluidity, which effectively suppresses the growth of sodium or potassium dendrites. However, the poor wettability of the NaK liquid alloy on conventional metal substrates is unfavorable for cell fabrication due to its strong surface tension. In this paper, low-density and low-cost fluorinated aluminum foam is used as a substrate support material for NaK liquid alloy. By combining low surface tension NaK@C with fluorinated aluminum foam, we obtain a uniformly distributed and structurally stable electrode material. The composite electrode has a cycling stability of more than 3000 hours in a symmetrical cell. Furthermore, when coupled with a sulfurized polyacrylonitrile cathode in carbonate electrolyte, it maintains excellent stability even after 800 cycles, with 72% of capacity retention.

To mitigate lithium dissolution and polysulfide shuttle effect phenomena in high energy lithium sulfur batteries (LISBs), a conductive, flexible, and easily modified polymer composite layer was applied on the anode. The polymer composite layer includes polyaniline and functionalized graphite. The electrochemical behavior of LISBs was studied by galvanostatic charge/discharge tests from 1.7 to 2.8 V up to 90 cycles and via COMSOL Multiphysics simulation software. No apparent overcharge occurred during the charge state, which suggests that the shuttle effect of polysulfides was effectively prevented. The COMSOL Multiphysics simulation provides a venue for optimal prediction of the ideal concentration and properties of the polymer composite layer to be used in the LISBs. The testing and simulation results determined that the polymer composite layer diminished the amount of lithium polysulfide species and decreased the amount of dissolved lithium ions in the LISBs. In addition, the charge/discharge rate of up to 2.0 C with a cycle life of 90 cycles was achieved. The knowledge acquired in this study was important not only for the design of efficient new electrode materials, but also for understanding the effect of the polymer composite layer on the electrochemical cycle stability.

It is important for researchers in material domain to reconstruct and visualize the microstructure of alloy, which helps discover morphologies and properties that can only be found in three dimensional and microscopic space. However, because of the limitation of state-of-the-art sensors, the internal microstructure of the material is not easy to obtain. In this paper, a novel automatic 3D reconstruction method is proposed using diffraction contrast tomography technology to capture the 3D microstructure of Al-La alloy. The pipeline of the proposed method starts from the imaging of Al-La alloy with the LabDCT technique from Carl Zeiss AG, which produces a sequence of 2D microstructure sections. Then, a segmentation algorithm based on superpixel and lifted multicut is proposed to extract the 2D microstructure in an image section. Finally, 2D segmentations are joined together to reconstruct and visulize the 3D microstructure. As a result, a novel morphology of Al-La alloy is recovered with both dendrite and lamellar morphologies. The proposed method has the advantage of the ability to losslessly recover the internal microstructure.

Despite being well established phenomena, solidification principles are experiencing tough challenges in their application to explain microscale transport phenomena in additive manufacturing melt pool. The problem becomes even more complicated when applied to multicomponent bulk metallic glass matrix composites (BMGMC) whose behavior is dubious and still not fully understood. The aim of the present study is to highlight pathways to overcome these challenges. A comprehensive nucleation and growth model based on original KGT theory and Rappaz modification is proposed encompassing actual transient thermophysical BMGMC data to predict evolving microstructure during additive manufacturing. The model is aimed at pictorial representation of in-situ ductile phase dendrite evolution from melt pool during solidification using two-dimensional cellular automaton (CA) methods. It is proposed to be coded in MATLAB® using commercial simulation code ABAQUS® at back end for macroscopic heat transfer model. The results will be compared with experimental values for validation.

Garnet-type Ta-doped Li7La3Zr2O12 (LLZO) ceramic solid electrolytes with Ga2O3 additive were synthesized via a conventional solid-state reaction process. When the amounts of Ga2O3 additive were below 2 mol %, the sintered sample has a dense structure composed of grains with the averaged size of 5 to 10 μm, while 3 mol % or more Ga2O3 addition causes the significant increase in grain size above several 10 to 100 μm, due to the sintering with large amount of liquid Li-Ga-O phase at high temperature. The highest total (bulk + grain-boundary) ionic conductivity of 1.1 mS cm1 at room temperature was obtained in the sample with 5 mol % Ga2O3 addition. However, in galvanostatic testing of the symmetric cell with Li metal electrodes, this sample was shorted by Li dendrite growth into solid electrolyte at current density below 0.2 mA cm2. The tolerance for Li dendrite growth is maximized in sample sintered with 2 mol % Ga2O3 addition, which was shorted at 0.8 mA cm2 in the symmetric cell. Since the interfacial resistance between Li metal and solid electrolyte was nearly identical among the all samples, the difference in tolerance for Li dendrite growth is mainly attributed to the difference in microstructure of sintered samples depending on the amounts of Ga2O3.

Cellular substructure has been widely observed in the sample fabricated by laser powder bed fusion, while its growth direction and the crystallographic orientation have seldom been studied. This research tries to build a general model to construct the substructure from its two-dimensional morphology. All the three Bunge Euler angles to specify a unique growth direction are determined, and the crystallographic orientation corresponding to the growth direction is also obtained. Based on the crystallographic orientation, the substructure in the single track of austenitic stainless steel 316L is distinguished between the cell-like dendrite and the cell. It is found that, with the increase of scanning velocity, the substructure transits from cell-like dendrite to cell. When the power is 200 W, the critical growth rate of the transition in the single track can be around 0.31 ms^-1.

Dendrite growth and parasitic reactions with liquid electrolyte are the two key factors that restrict the practical application of the lithium metal anode. Herein, a bis(benzene sulfonyl)imide based single-ion polymer artificial layer for lithium metal anode is successfully constructed, which is prepared via blending the as-prepared copolymer of lithiated 4, 4’-dicarboxyl bis(benzene sulfonyl)imide and 4,4’-diaminodiphenyl ether on the surface of lithium foil. This single-ion polymer artificial layer enables compact structure with unique continuous aggregated Li+ clusters, thus reducing the direct contact between lithium metal and electrolyte, and ensuring Li+ transport fast and homogeneous simultaneously. Based on which, the coulombic efficiency of the Li|Cu half-cell is effectively improved, and the cycle stability of the Li|Li symmetric cell can be prolonged from 160 h to 240 h. Surficial morphology and elemental valence analysis confirm that the bis(benzene sulfonyl)imide based single-ion polymer artificial layer effectively facilitates the Li+ uniform deposition and suppresses parasitic reactions between lithium metal anode and liquid electrolyte in the LFP|Li full-cell. This strategy provides a new perspective to achieve steady lithium metal anode, which can be a promising candidate in practical application.

There has been controversy around the mechanical properties of Mg-alloys such as AZ91D and the large variation of these have been seen. The current paper addresses this controversy through specially fabricated samples combined with tensile testing and advanced metallography, including 3D reconstruction of the phases. The results show that despite a more brittle nature of the fracture, the equiaxed microstructure displays a better elongation as compared to a dendritic microstructure. The main conclusion is that this is primarily caused by the nature, or tortuosity, of the Mg17Al12-network in the material.

Lithium-metal batteries offer high energy density, but are challenged by dendrite growth, which can lead to short circuits and battery failure. Various models with varying degrees of accuracy and computational cost have been developed to understand and predict dendrite growth. In this study, a simple simulation model to predict macroscale dendrite growth on lithium metal electrodes is presented. The model uses a 3D single-particle diffusion-limited aggregation (DLA) algorithm, biased by the electric field, to simulate dendrite growth. The model was validated using 3D MRI of dendrite growth in a lithium symmetric cell. It was used to simulate deposition between consecutive measured dendrite structures. The model also introduces an important parameter, namely the biasing factor c, which determines the balance between diffusion and electric field effects. This parameter was calibrated using the overlap and displacement of deposition sites metrics, achieving optimal results at c = 0.7. The model predictions were in good agreement with experimental data confirmed by fractal dimension analysis. This model provides a useful tool for predicting and studying dendrite formation in lithium and other metal batteries.

The effects of chemical composition and solidification rate on the solidification behavior of high-Cr white irons were investigated through directional solidification. Increasing the solidi-fication rate in hypoeutectic alloys caused the finer dendrite arm spacing as expected. The eutec-tic structure which formed in the interdendritic region comprised of M7C3 and austenite, how-ever, secondary dendrite arms of hypoeutectic alloys contained a few M7C3 particles that solidi-fied prior to the eutectic structure. The transition from cellular to dendritic solidification oc-curred at a solidification rate between 50 µm/s and 100 µm/s in a near eutectic alloy. In the near eutectic alloy with cellular solidification, a directionally arrayed in-situ composite of M7C3/austenite formed within the cell. Speckle-like feature appeared in the intercellular region due to M23C6 carbide precipitation during subsequent cooling after freezing. Like dendrite arm spacing in hypoeutectic alloys, the inter-speckle spacing and the inter-fibre spacing became finer with increasing solidification rate in the cellular solidification range.

Rechargeable solid-state batteries (SSBs) offer enhanced safety, higher energy density, and longer cycle life compared with conventional lithium-ion batteries, making them a promising solution for electric vehicles, grid storage, and other high-demand applications. However, challenges such as interface stability, low ionic conductivity, and manufacturing scalability hinder their commercial viability. This research provides a comprehensive cross-sectional thematic and bibliometric analysis of recent SSB research, focusing on four key areas: electrolyte engineering, electrode engineering, battery architecture, and performance evaluation. By analyzing publications from major databases, this study highlights the latest innovations, including improved solid electrolytes, advanced electrode materials, and novel architectures that enhance both performance and manufacturability. The findings offer valuable insights for researchers, engineers, and industry stakeholders by identifying critical gaps in the field and highlighting future research directions. The work examines progress in interface optimization, ion transport improvements, and scalable production techniques, which are crucial for advancing SSB technology. By presenting a detailed review of key developments and challenges, this study contributes to a deeper understanding of SSB progress and its potential to revolutionize the energy storage industry. The results will guide researchers in targeting high-impact areas and help industry leaders and policymakers strategize the commercial deployment of SSBs in electric vehicles, stationary energy storage, and other applications requiring reliable and efficient energy solutions.