Enhancing the corrosion resistance of mullite-based composites for the calcination of Li-ion battery cathode materials via adding potassium feldspar

Based on the degradation mechanism of refractory saggar involving penetration and corrosion by Li-ion battery (LIB) cathode materials, developing refractory composites with a contiguous corrosion resistant materials network structure are considered one of the most promising ways to simultaneously achieve enhanced penetration resistance and corrosion resistance in saggar materials. Here, a mullite-based composites with a contiguous K 2 O-Al 2 O 3 -SiO 2 amorphous phase (KASp) network structure were simply prepared by incorporating potassium feldspar. The resulting material features a contiguous KASp network structure and exhibits low connectivity pores. This structure significantly enhances the composites resistance to penetration and corrosion by LIB cathode materials, primarily due to the combined effects of the KASp physical barrier and reduced pore continuity. Additionally, the strong KASp and mullite/corundum interfacial bonding reinforce the composites, leading to exceptional mechanical strength.