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The interplay between stack pressure, mechanical expansion and degradation pathways in lithium-ion batteries
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DOI：10.1038/s41560-026-02087-6.png)
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Abstract
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While electrochemical degradation mechanisms in lithium-ion batteries are well studied, the influence of mechanical factors remains poorly understood. Here we introduce a high-precision stack-pressure control and dilatometry tool to apply a uniform and constant stack pressure on electrodes independent of electrode swelling. By increasing stack pressure fourfold over typical initial values, we double the lifetime of graphite ‖ LiNi0.8Mn0.1Co0.1O2 cells, an industrially relevant battery chemistry, without altering active materials or electrolytes. This suggests that many lithium-ion batteries operate under sub-optimal stack-pressure conditions, leading to curtailed lifetimes. We demonstrate that different degradation mechanisms emerge outside the optimal pressure window: low stack pressure accelerates cathode cracking, whereas high pressure promotes lithium plating. Our findings highlight coupled mechanical–electrochemical degradation mechanisms and identify stack-pressure optimization as a practical solution for increasing cycling stability. While electrochemical degradation in lithium-ion batteries is well studied, the role of stack pressure in long-term cycling remains unclear. Here the researchers use a high-precision pressure-controlled dilatometry tool to optimize stack pressure and understand how it prolongs battery lifetime.
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