The interface engineering and structure design of an alloying-type metal foil anode for lithium ion batteries: a review

An alloying-type metal foil serves as an integrated anode that is distinct from the prevalent powder-casting production of lithium ion batteries (LIBs) and emerging lithium metal batteries (LMBs), and also its energy density and processing technology can be profoundly developed. However, besides their apparent intriguing advantages of a high specific capacity, electrical conductivity, and the ease of formation, metal foil anodes suffer from slow lithiation kinetics, a trade-off between specific capacity and cycle life, and a low initial Coulombic efficiency (ICE) owing to their multi-scaled structural geometry, huge volume change, and induced interfacial issues during the alloying process. In this review, we attempt to present a comprehensive overview on the recent research progress with respect to alloying-type metal foil anodes toward high-energy-density and low-cost LIBs. The failure mechanism of metal foil anodes during lithiation/delithiation and existing challenges are also summarized. Subsequently, the structural design and interface engineering strategies that have witnessed significant achievements are highlighted, which can promote the practical development of LIBs, including artificial SEI, alloying, structural design, and grain refinement. Furthermore, scientific perspectives are proposed to further improve the overall performance and decouple the complex mechanisms in terms of interdisciplinary fields of electrochemistry, metallic materials science, mechanics, and interfacial science, demonstrating that metal foil anode-based LIBs require more research efforts. This review presents a comprehensive overview on alloying-type metal foil anodes toward high energy density and low-cost LIBs, calling for more attempts in the interdisciplinary fields of electrochemistry, metallic materials science, and mechanics.