With the rapid development of the Electric Vehicle (EV) industry, the importance of batteries as its core component has become increasingly prominent. The performance, cost, and lifespan of EV batteries largely depend on the quality of their upstream raw materials. This article provides a detailed overview of the key powder materials required in the production of EV batteries.

Lithium

Currently, lithium batteries are the mainstream power choice for new energy vehicles. Lithium, as a key element in EV batteries, is supplied primarily in powder form. Common lithium powders include lithium carbonate (Li₂CO₃) and lithium hydroxide (LiOH·H₂O).

Lithium Carbonate (Li₂CO₃) is a raw material for manufacturing various lithium-based cathode materials (such as LiFePO₄, LiCoO₂, NCM). It provides the necessary lithium ions for the battery, which are crucial for energy storage. High-purity lithium carbonate ensures stable performance of cathode materials, improving the battery's energy density and cycle life.

Lithium Hydroxide (LiOH·H₂O) is mainly used in the production of high-nickel cathode materials (such as NCA LiNiCoAlO₂). It enhances the battery's energy density and cycle life by combining with high-nickel materials. In high-performance batteries, lithium hydroxide helps improve overall performance and stability.

Cobalt

Cobalt is primarily used in EV batteries to manufacture high-energy-density cathode materials. Cobalt oxide (Co₃O₄) is a common form of cobalt powder, typically obtained through the roasting and oxidation of cobalt ore. Cobalt oxide is widely used in the production of lithium cobalt oxide (LiCoO₂) and lithium nickel cobalt aluminum oxide (NCA), enhancing the battery's stability and energy density. Another important cobalt compound is cobalt carbonate (CoCO₃), which serves as an intermediate for cathode materials and is further processed to form the final active substance.

Fig 1. Role of Cobalt in Batteries: Increases energy density.

Despite its importance, cobalt faces a challenging reality. It is estimated that in 1 ton of lithium cobalt oxide, the lithium content is only 0.07 tons, while the cobalt content is 0.61 tons, more than 8 times that of lithium. However, cobalt's abundance in the Earth's crust is only one-sixth that of lithium. Given its high cost and safety concerns (poor thermal stability), manufacturers are striving to reduce cobalt usage in batteries. Elon Musk has stated that Tesla aims to reduce cobalt usage from 3% to 0%. Currently, increasing the nickel content in ternary lithium batteries is an industry consensus.

Nickel

Nickel also enhances energy density and cycle life, and importantly, it is inexpensive. Nickel oxide (NiO) is the primary form of nickel powder, mainly used in the production of NCM (lithium nickel manganese cobalt oxide) and NCA cathode materials. Nickel hydroxide (Ni(OH)₂) is a precursor for nickel-based cathode materials, ensuring high performance and consistency.

Manganese

Manganese plays a significant role in the production of EV batteries. Its inclusion reduces battery costs while improving thermal stability and safety.

• Manganese Oxide (MnO₂): Used in the production of Lithium Manganate (LiMn₂O₄) and NCM cathode materials, manganese oxide provides good thermal stability and electrochemical performance.
• Manganese Carbonate (MnCO₃): Acts as an intermediate for manganese-based cathode materials, ensuring stable performance.

Manganese-based materials are sometimes used as conductive additives or surface coatings to enhance electrode conductivity and structural stability, such as nano-manganese oxide and manganate, which improve the conductive network and interface compatibility of electrode materials.

Graphite

Graphite is a commonly used anode material in EV batteries. It comes in two forms: natural graphite powder and synthetic graphite powder.

Natural Graphite Powder, obtained by mining natural graphite ore and crushing/sieving, it is mainly used in standard anode materials. This natural material is responsible for the intercalation and deintercalation paths of lithium ions, affecting the battery's capacity and lifespan.

Synthetic Graphite Powder is produced through methods like chemical vapor deposition (CVD), offering higher purity and uniform particle size. This makes it suitable for high-performance batteries by improving consistency and cycle stability.

Metal Powders

In addition to the aforementioned compound powders and graphite powders, certain metal powders are also used in EV battery production. Copper powder and aluminum powder are important components of electrode current collectors, supplied in powder form.

• Copper Powder: Mainly used for anode current collectors, requiring high conductivity and good mechanical strength.
• Aluminum Powder: Used for cathode current collectors, requiring lightweight and high conductivity.

These metal powders ensure the overall conductivity of the electrodes, facilitating efficient energy transfer in the battery.

Additive Powders

Functional additives are used in EV batteries to enhance performance and safety. Aluminum oxide (Al₂O₃) and zinc oxide (ZnO) are common additive powders.

• Aluminum Oxide (Al₂O₃): Used in the production of solid electrolytes or electrode coatings, it improves battery stability and prevents side reactions.
• Zinc Oxide (ZnO): Used to regulate the battery's interface properties, improving cycle performance and overall stability.

These additives optimize the battery's internal structure and chemical environment, extending its lifespan and enhancing overall performance.

Conclusion

Lithium, cobalt, nickel, and manganese are critical for cathode materials, each contributing to energy density, stability, and cost-effectiveness. Meanwhile, graphite is essential for anode materials, influencing battery capacity and lifespan. What’s more, metal powders (copper and aluminum) ensure efficient energy transfer in electrodes. Apart from it, additives (Al₂O₃, ZnO) enhance battery performance, safety, and longevity.

Stanford Advanced Materials (SAM) offers a variety of powder materials for EV battery production, including lithium, cobalt, nickel, graphite, copper, aluminum, aluminum oxide (Al₂O₃), and zinc oxide (ZnO). If you have related ordering needs, please feel free to obtain more information from our sales representatives through "Get A Quote" or "Leave A Message".

Table 1. which powders are used in EV batteries