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Effects of sputtering power on the growth behavior and high-voltage stability of Al/PET/Al composite current collectors
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DOI：10.1016/j.vacuum.2026.115688.png)
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Abstract
En 中文
Lightweight polymer-based Al composite current collectors (Al CCCs) are promising for reducing inactive mass in lithium-ion batteries, but the relationships among sputtering parameters, microstructure, defects, adhesion, and high-voltage corrosion stability remain insufficiently understood. Herein, symmetric Al/PET/Al CCCs were fabricated by DC magnetron sputtering on both sides of an 8 μm PET substrate, with each Al layer controlled to approximately 1 μm. By varying sputtering power from 10 to 250 W, power-dependent film growth, corrosion resistance, adhesion, and electrochemical stability were systematically investigated. Increasing sputtering power promoted Al island coalescence, film densification, crystallographic ordering, and strain relaxation. Surface porosity decreased from 0.38% at 10 W to 0.17% at 200 W, while the lowest roughness was obtained at 200 W. However, excessive power caused local surface heterogeneity and roughening. Intermediate sputtering powers, especially 150 W, produced a balanced film state with compact morphology, low surface oxidation, strong adhesion, and reduced corrosion tendency. In LiFePO4||Li cells operated at 2.4–4.2 V, all samples showed similar cycling behavior. In high-voltage LiNi0.5Mn1.5O4||Li cells operated at 3.0–4.9 V, the 150 W coating delivered superior stability, retaining 85.6 mAh g−1 after 500 cycles. These results highlight the importance of optimizing the sputtering-growth window for polymer-supported Al CCCs.
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