Engineering and Optimization of Silicon–Iron–Manganese Nanoalloy Electrode for Enhanced Lithium-Ion Battery

The electrochemical performance of a battery is considered to be primarily dependent on the electrode material. However, engineering and optimization of electrodes also play a crucial role, and the same electrode material can be designed to offer significantly improved batteries. In this work, Si–Fe–Mn nanomaterial alloy (Si/alloy) and graphite composite electrodes were densified at different calendering conditions of 3, 5, and 8 tons, and its influence on electrode porosity, electrolyte wettability, and long-term cycling was investigated. The active material loading was maintained very high (~2 mg cm −2 ) to implement electrode engineering close to commercial loading scales. The densification was optimized to balance between the electrode thickness and wettability to enable the best electrochemical properties of the Si/alloy anodes. In this case, engineering and optimizing the Si/alloy composite electrodes to 3 ton calendering (electrode densification from 0.39 to 0.48 g cm −3 ) showed enhanced cycling stability with a high capacity retention of ~100% over 100 cycles.