An artificial aluminum-tin alloy layer on aluminum metal anodes for ultra-stable rechargeable aluminum-ion batteries.

Rechargeable aluminum ion batteries (RAIBs) exhibit great potential for next-generation energy storage systems owing to the abundant resources, high theoretical volumetric capacity and light weight of the Al metal anode. However, the development of RAIBs based on Al metal anodes faces challenges such as dendrite formation, self-corrosion, and volume expansion at the anode/electrolyte interface, which needs the rational design of an aluminum anode for high-performance RAIBs. This work proposes a novel and low-cost strategy by utilizing an alloy electrodeposition method in a low-temperature molten salt system to fabricate an aluminum-tin (AlSn) alloy coating layer on copper foil as the anode for RAIBs, which successfully addresses the issues of dendrite formation and corrosion at the anode/electrolyte interface. The artificial AlSn alloy layer could enhance the active sites for metal Al homogeneous deposition and effectively retard the dendrite formation, which was verified by an optical microscopy study. The symmetric AlSn@Cu cell demonstrates a low average overpotential of ∼38 mV at a current density of 0.5 mA cm and a long-term lifespan of over 1100 h. Moreover, the AlSn@Cu//MoS full cells deliver a high capacity of 114.9 mA h g at a current density of 100 mA g and maintain ultra-stable cycling stability even over 1400 cycles with a ∼100% coulombic efficiency (CE) during the long-term charge/discharge processes. This facile alloy electrodeposition approach for designing high-performance Al-based anodes provides insights into the understanding of artificial interface chemistry on Al-based anodes and potentially accelerates the design of high-performance RAIBs.