Design and preparation of novel Na4Ca3(AlO2)10 material with superior corrosion resistance to alkali erosion

Sodium-ion battery (SIB), as a crucial supplement to lithium-ion battery (LIB), have shown significant application value in the field of large-scale energy storage and electric vehicles. However, the alkali erosion problem triggered by its cathode materials during high-temperature synthesis will become a key bottleneck restricting its industrialization. In this study, we broke through the traditional passive protection strategy, and based on the deepening and expanding of established protocol of stable coexistence of alkali erosion products and their corresponding homologous alkali metal compounds (EPAMC), we innovatively designed and verified the functionalization application of Na 4 Ca 3 (AlO 2 ) 10 (N 2 C 3 A 5 ) in the synthesis to SIB cathode material. The results show that under the simulated industrial calcination conditions (850 °C/12 h), the erosion depth of N 2 C 3 A 5 is only 56.33 ± 23.82 μm, which is significantly better than that of the traditional material system, and the erosion mechanism is recognized as “melt-penetration”. Compared with the control group, the apparent porosity of the experimental group decreased by 20.08 ± 2.57 %, and the residual strength retention after three cycles increased by 10.11 ± 0.05 %. It is noteworthy that this study provides new ideas for the first time to crack the alkali erosion challenge from the perspective of elemental composition and physical phase design, accelerates the exploration of novel alkali erosion-resistant materials, and is of great guiding significance for advancing the engineering application of energy storage materials .