Electrochemical Characterization of Al/C “Surge” Electrode in Lithium Half-Cells: Proof-of-Concept and Cu-Backer Approach

Abstract

This study presents the electrochemical characterization of a novel, binder-free, plasma-treated aluminum/carbon electrode (“Surge”) using lithium metal half-cells. The low operating potential near 0 V vs. Li/Li+ enables the investigation of the electrode’s charge storage mechanisms and stability limits. We compare its electrochemical behavior in coin cells (CR2032) against two reference configurations: (i) the Surge electrode with a thin copper backer (Surge + Cu-backer) and (ii) a commercial graphite electrode on an aluminum current collector (C-REF). The Surge electrode demonstrated ultra-high initial specific capacities of up to approximately 4500 mAh/g (cycle 1) with Coulombic efficiencies exceeding 85% after the formation cycle. The observed capacity significantly exceeds the theoretical value for Li-Al alloying (993 mAh/g), indicating that lithium plating within the porous carbon scaffold contributes substantially to the total charge storage. However, this high performance was limited to approximately 8 to 9 stable cycles. Post-cycling analysis via scanning electron microscopy combined with energy-dispersive X-ray spectroscopy (SEM/EDX) revealed a dominant failure mechanism: partial dissolution and consumption of the Al current collector leading to material redistribution. Quantitative EDX analysis showed a decrease in Al content from 45 at.% to 12 at.% alongside an increase in oxygen content from 8 at.% to 38 at.%, suggesting extensive Al-oxide formation. Critically, in the absence of a backer, Al-containing material deposited onto the stainless-steel cell components. The Cu backer served to redirect these deposits, improving current collection and modestly extending the short-term durability to approximately 1800 mAh/g at cycle 14 (approximately 75% capacity retention). In contrast, the C-REF control cell reached only approximately 1000 mAh/g (cycle 4) before failing within 5 to 6 cycles, underscoring the inherent instability of bare Al at low potentials. This characterization study establishes the Surge architecture as a successful proof-of-concept for ultra-high capacity charge storage and identifies Al dissolution as the dominant degradation mechanism. Future optimization must focus on stabilizing the Al substrate through protective interphases, alloying, or electrolyte engineering.

Key findings

• ▸The Surge electrode demonstrates high initial specific capacities exceeding the theoretical value for Li-Al alloying.
• ▸Lithium plating within the porous carbon scaffold contributes substantially to the total charge storage.
• ▸The dominant failure mechanism is revealed by post-cycling analysis via SEM/EDX.

Keywords

Identifiers

DOI

10.3390/en19041076

Journal

Energies

Year

2026