Fatigue Strength and Damage Behavior of Micron-Thick Ultrathin Current Collector Cu Foil and Al Foil for Lithium-Ion Battery

doi:10.11900/0412.1961.2022.00523

Acta Metall Sin

2024, Vol. 60

Issue (4): 522-536 DOI: 10.11900/0412.1961.2022.00523

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Fatigue Strength and Damage Behavior of Micron-Thick Ultrathin Current Collector Cu Foil and Al Foil for Lithium-Ion Battery

CHENG Fulai¹^,², LUO Xuemei¹(

), HU Bingli¹^,², ZHANG Bin³, ZHANG Guangping¹(

)

1 Shenyang National Laboratory for Materials Science, Institute of Metal Research, Chinese Academy of Sciences, Shenyang 110016, China
2 School of Materials Science and Engineering, University of Science and Technology of China, Shenyang 110016, China
3 Key Laboratory for Anisotropy and Texture of Materials, Ministry of Education, School of Materials Science and Engineering, Northeastern University, Shenyang 110819, China

Cite this article:

CHENG Fulai, LUO Xuemei, HU Bingli, ZHANG Bin, ZHANG Guangping. Fatigue Strength and Damage Behavior of Micron-Thick Ultrathin Current Collector Cu Foil and Al Foil for Lithium-Ion Battery. Acta Metall Sin, 2024, 60(4): 522-536.

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Abstract

With the rapid development of high-performance and high-energy-density lithium-ion batteries, lightweight current collector metal foils for lithium-ion batteries have become a crucial direction of industrial technological advancements. As the thickness of the current collector decreases, the fatigue failure problem becomes increasingly prominent. Once the fatigue failure of the current collector occurs, it will have a catastrophic impact on the electrochemical and safety performances of lithium-ion batteries. Here, to further clarify the fatigue damage mechanism of current collector foils, the high cycle fatigue strength and fatigue failure behavior of current collector Cu and Al foils for lithium-ion batteries under cyclic loading were experimentally investigated using tensile-tensile fatigue test and the EBSD technique. Results show that the fatigue cracks of the Cu foils mainly originate from the slip bands with larger grain sizes and propagate along the slip bands. Based on the microstructure observation and analysis of damaged grains, a statistical relationship between fatigue crack initiation and microstructure (grain size and its coefficient of variation, grain orientation, and Schmid factor (Ω)) of the Cu foils was obtained. Due to the presence of rolled defects on the surface of Al foils, the fatigue cracks are preferentially initiated at the surface defects. Extreme value statistics accurately predicted the possible defect population and the largest defect size in the Al foils, and the relationship between the defect size and fatigue limit was established using the Kitagawa-Takahashi diagram.

Key words: high cycle fatigue crack initiation ultrathin foil Kitagawa-Takahashi diagram current collector lithium-ion battery

Received: 14 October 2022

ZTFLH:

TG146

Fund: National Natural Science Foundation of China(52071319)

Corresponding Authors: ZHANG Guangping, professor, Tel:(024)23971938, E-mail: gpzhang@imr.ac.cn;
LUO Xuemei, associate professor, Tel:(024)83978029, E-mail: xmluo@imr.ac.cn

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	CHENG Fulai
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	HU Bingli
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	ZHANG Guangping

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https://www.ams.org.cn/EN/10.11900/0412.1961.2022.00523 OR https://www.ams.org.cn/EN/Y2024/V60/I4/522

Fig.1 SEM images of surface morphologies (a, b), TEM images of microstructures (c, d), and grain size distributions (e, f) of Cu foils with thicknesses of 6 μm (a, c, e) and 8 μm (b, d, f)

Fig.2 Engineering stress-strain (a) and stress amplitude-fatigue life (b) curves of Cu foils with different thicknesses (The arrows indicate that the specimen is not failure under this stress amplitude and cycle)

Fig.3 Microstructures and damage features of fatigue damage initiation sites in 8 μm-thick Cu foils under a stress amplitude of 92 MPa and fatigue life of 4 × 10⁶ cyc (The arrows in Figs.4a-c represent fatigue damage sites. Black and white lines in Figs.4b and c are grain boundaries and twin boundaries, respectively)
(a) SEM image (LD—loading direction) (b) EBSD grain orientation map (ND—normal direction)
(c) Schmid factor map (d) post-fatigue TEM image
(e, f) inverse pole ﬁgures depicting the orientations of parent and twin grains associated with the fatigue damage in the surface ND (e) and LD (f), respectively

Slip

system

(

1 ¯

11)

(111)

(11

1 ¯

)

(

1 ¯

1 ¯

)

[01 1 ¯]

[1 ¯ 0 1 ¯]

[110]

[01 1 ¯]

[

1 ¯ 01

]

[

1 ¯ 10

]

[011]

[

1 ¯ 0 1 ¯

]

[

1 ¯ 10

]

[110]

[

1 ¯ 01

]

[011]

Parent

0.497

0.20

0.30

0.22

0.06

0.28

0.23

0.11

0.34

0.32

0.16

0.48

Twin

0.19

0.04

0.15

0.35

0.15

0.20

0.30

0.15

0.45

0.497

0.26

0.24

Table 1 Schmid factors (Ω) for the 12 slip systems of a pair of parent and twin in Fig.3b (Bold values indicate maximum Schmid factors (Ω_max))

Fig.4 SEM images of surface morphologies (a, b), TEM images of microstructures (c, d), and grain size distributions (e, f) of Al foils with thicknesses of 10 μm (a, c, e) and 13 μm (b, d, f)

Fig.5 Engineering stress-strain (a) and stress amplitude-fatigue life (b) curves of Al foils with different thicknesses (The arrows indicate that the specimen is not failure under this stress amplitude and cycle)

Fig.6 3D topography, schematic of surface defect, and distributions of defect size and defect parameter ( $a r e a$ ) for Al foils with different thicknesses
(a) 3D laser confocal image
(b) schematic of surface defect and the cross-sectional morphology along the AA' line
(c-f) distributions of defect size (c, d) and defect parameter (

a r e a

) (e, f) of 10 μm (c, e) and 13 μm (d, f) Al, respectively (d_depth—defect depth, d_length—defect length, d_width—defect width)

Fig.7 Surface damage morphology (a) and high magnified (b) SEM images, and EBSD characterization (c) of 13 μm-thick Al foils under a stress amplitude of 64 MPa and fatigue life of 1.4 × 10⁶ cyc (Black line, gray line, and red line in Fig.7c represent high angle grain boundaries (> 10°), low angle grain boundaries (2°~10°), and crack propagation path, respectively)

Fig.8 Grain configurations favoring fatigue crack initiation for Cu foils
(a) grain size, maximum Schmid factor (Ω_max), and normalized elastic modulus difference of the twin and parent grain pairs which present crack initiation and no crack initiation
(b) grain size (D) and Ω_max of the twin and parent grain pairs which present crack initiation and no crack initiation

Fig.9 Schematic of damage grain and surrounding grain inhomogeneity (a) and characteristics of grain inhomogeneity favorable to crack initiation (b) (All grains presenting crack initiation and no crack initiation have a high Ω_max (≥ 0.44), large grain size (≥ 5 μm), and grain orientation close to <100>_ND. γ—coefficient of variation)

Fig.10 Extreme value statistics predicting maximum defect size
(a) linear fitting for parameters of Gumbel function for Al foils with different thicknesses (

a r e a i

—Murakami defect size parameter, G(

a r e a i

)—cumulative probability of defect size)
(b) prediction of the maximum defect size under 95% probability

Fig.11 Kitagawa-Takahashi diagram of the Al foils with different thicknesses described by the El-Haddad formulation considering the expected defect distribution (Data points of the black rhombus and blue circle are the experimental fatigue limit (from Fig.5b), and shaded areas of black and blue lines are the cumulative probability of defect size (from Fig.10b) for Al foils with thicknesses of 10 and 13 μm, respectively; R—fatigue stress ratio; $a r e a 0$ —intrinsic defect size)

Thickness

Predicted

Experimental

μm

G( $a r e a$ )

a r e a m a x

μm

σ_w

MPa

σ_w

MPa

Deviation

6.13

+4.1

5.13

-1.9

Table 2 Fatigue limit predictions (from Fig.11) and experimental results (from Fig.5b) of Al foils with thicknesses of 10 and 13 μm

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