Lithium plating occurs when lithium ions fail to intercalate into the graphite anode during fast charging or low-temperature conditions. Instead, metallic lithium deposits accumulate unevenly on the anode surface, undermining the battery’s capacity and significantly raising safety risks. These metallic deposits not only diminish charge capacity irreversibly but potentially form dendritic structures that penetrate internal components, leading to short circuits and thermal runaway. Consequently, managing lithium plating is paramount for enhancing battery durability and user safety in EV applications.

Traditional charging protocols predominantly rely on fixed current schedules, designed without accommodating the nuanced realities of battery state and environmental variations. Such rigidity neglects the complex, dynamic changes in battery chemistry brought about by operating temperature, aging, and cycling history. Recognizing this, the IITGN team devised a smart charging algorithm that continuously adapts to a battery’s real-time condition, essentially “listening” to its internal responses to modulate charging intensity and prevent damage before it starts.

The adaptive strategy, termed Multi-Step Constant Current (MSCC) charging, optimizes the charging process across five distinct current stages finely tuned according to two pivotal parameters: State of Age (SOA) and Battery Ambient Temperature (BAT). Unlike conventional methods which assume a generic “new battery at room temperature,” MSCC dynamically adjusts thresholds at the onset of each charge cycle. This proactive calibration ensures the current steps respond precisely to shifting electrochemical conditions, thereby avoiding the onset voltage where lithium plating initiates.

Crucial to the efficacy of this approach is an innovative monitoring technique developed by the researchers to detect incipient lithium plating. By employing Rest-Interrupted Constant Current (RICC) testing, the charging current is momentarily paused at intervals to measure minute variations in internal impedance, which correlate strongly with the onset of metallic lithium deposition. This precise impedance sensing, combined with advanced statistical optimization through the Taguchi method, allowed the team to define optimal currents for each charging step tailored to mitigate plating under varied operational stressors.

The experimental validation leveraged Panasonic NCR18650B cells, a commercial nickel-cobalt-aluminium (NCA) lithium-ion chemistry widely used in EV applications due to its high energy density. Testing spanned a challenging temperature spectrum from -5°C to 25°C and encompassed fresh and aged battery states (up to 15% degradation). Results demonstrated that the adaptive MSCC strategy not only enhanced charge capacity utilization by over 10% but also achieved improvements in charging efficiency by approximately half a percent compared to existing plating-aware techniques. These seemingly modest efficiency gains underscore substantial improvements in battery longevity and risk mitigation.

By shifting protective mechanisms from hardware-intensive, often bulky and costly systems toward an intelligent, software-defined supervisory model, this innovation holds profound implications for the integration of adaptive algorithms within existing Battery Management Systems (BMS). This software-centric approach enables real-time, fine-grained control over charging currents without significant changes to physical hardware, offering manufacturers and users enhanced battery protection while maintaining user expectations for rapid charging.

The broader implications resonate strongly with ambitious policy initiatives targeting widespread EV adoption, particularly in India. National programs such as Faster Adoption and Manufacturing of Electric Vehicles (FAME) and the Advanced Chemistry Cell (ACC) Battery Storage initiative underscore a growing commitment to electrification. Success in these ventures hinges on robust battery technologies capable of thriving in diverse environmental climates and enduring long-term operational stresses — conditions under which adaptive charging strategies like MSCC are expected to excel.

Globally, the demand for nickel-rich lithium-ion batteries continues to surge, driven by the high energy density necessary for extended EV range. Yet, the same characteristics that make these cells ideal for energy storage simultaneously accentuate vulnerability to lithium plating during fast charging and temperature variations. IITGN’s adaptive framework thus aligns with worldwide efforts to enhance battery resilience, offering a scalable path to prolong battery lifespans and reduce the environmental footprint of EV batteries.

Moreover, advancing smart charging infrastructure that can adjust dynamically aligns well with evolving trends in battery warranty policies and consumer expectations. As manufacturers envisage extended warranties premised on battery health, intelligent charging solutions become indispensable for safeguarding asset value and user satisfaction. Such technology promises to reconcile the often conflicting imperatives of rapid recharge times and long-term battery reliability.

Fundamentally, the research exemplifies a paradigm shift in battery management — from static, one-size-fits-all charging to nuanced, data-driven strategies that respect the intricate, evolving electrochemical environment inside lithium-ion cells. Its success not only heralds improvements in EV battery safety and efficiency but also sets a benchmark for integrating adaptive control algorithms into next-generation energy storage solutions.

Looking ahead, future commercial adoption of the MSCC charging methodology could significantly reduce the reliance on bulky hardware safeties, lower the total cost of ownership for EV users, and even contribute to the sustainability of lithium-ion battery supply chains by curbing premature capacity loss. As rapid electrification accelerates worldwide, such pioneering research will be pivotal in ensuring the reliability and environmental viability of emerging battery technologies.

In conclusion, the IIT Gandhinagar team’s adaptive multi-step constant current charging strategy stands out as a seminal contribution to battery science and electric mobility. By intelligently mitigating lithium plating across varying temperatures and battery aging conditions, it paves the way for smarter, safer, and more durable EV batteries — reinforcing the critical role of algorithmic innovation in the future of sustainable transportation.

Subject of Research: Development of an optimized adaptive charging strategy to prevent lithium plating in lithium-ion batteries.

Article Title: Development of an optimized adaptive multi-step constant current charging strategy to prevent lithium plating in lithium-ion batteries.

News Publication Date: 27-Apr-2026.

Web References:
https://www.sciencedirect.com/science/article/pii/S2352152X26020049
http://dx.doi.org/10.1016/j.est.2026.122340

Image Credits: Please credit the Smart Power Electronics Laboratory, IIT Gandhinagar.

Keywords

Lithium-ion battery, lithium plating, adaptive charging, electric vehicles, battery degradation, battery management system, fast charging, battery impedance, state of age, battery ambient temperature, multi-step constant current, battery durability

ASSBs have long been regarded as the “dream battery” by scientists and engineers. Their intrinsic advantage lies in replacing the traditional organic liquid electrolyte and graphite anodes with solid electrolytes and lithium metal, respectively. This substitution dramatically reduces the risk of fire—one of the dominant safety concerns with conventional lithium-ion batteries—while offering substantially improved energy density. However, the Achilles’ heel of these batteries has been the high interfacial resistance caused by unstable contact between the solid electrolyte and lithium metal anode, which impedes efficient ion flow and leads to the formation of lithium dendrites. These dendritic structures are microscopic, tree-like lithium deposits that pose severe risks to battery longevity and safety by penetrating the electrolyte and triggering short circuits.

To tackle these pervasive challenges, many research efforts have resorted to applying external pressure during battery operation—often up to tens of megapascals (MPa)—or employing complex, costly surface coatings to stabilize the lithium-solid electrolyte interface. Despite their effectiveness in experimental settings, these methods are impractical for real-world applications like electric vehicles. The heavy and bulky pressurization systems add weight and reduce space efficiency, undermining the primary advantages of ASSBs. Additionally, the complexity and expenses associated with sophisticated coatings escalate manufacturing costs, further hindering scalability and commercial viability.

KERI’s innovative approach circumvents these issues by introducing a delicate yet robust nano-tin (Sn) interlayer directly onto the lithium metal anode’s surface. This interlayer is composed of nano-sized tin particles possessing strong lithium affinity and excellent lithium storage capability. Utilizing a transfer printing technique, the researchers stamped this nano-Sn powder thin film uniformly onto the lithium metal’s surface, creating a highly effective buffer layer that facilitates stable, intimate contact with the solid electrolyte. This strategy dramatically reduces the physical degradation of lithium metal by minimizing interfacial resistance and simultaneously provides a more efficient ion transport pathway, leading to significant overall resistance reduction in the battery cell.

The implications of this technological breakthrough were emphatically demonstrated when the research team applied their nano-Sn interlayer to a pouch cell configuration—a key step towards industrially relevant battery formats. The resulting battery displayed a remarkable capacity retention exceeding 81% after 500 charge-discharge cycles under an external pressure as low as 2 MPa, a performance accompanied by an outstanding energy density greater than 350 Wh/kg. To put this into perspective, this value surpasses that of typical commercial lithium-ion batteries, which usually range between 150 to 250 Wh/kg. Such performance signifies a leap forward in realizing lightweight, powerful, and long-lasting all-solid-state batteries without the cumbersome mechanical pressurization of previous methods.

Beyond the engineering feats, KERI’s research integrates advanced theoretical insights as well. Collaborating with Dr. Kim Youngoh of the Next-Generation Battery Research Center at KERI, the team conducted first-principles computational simulations that delve into the atomic and electronic structure of the lithium-tin interface. These simulations clarified the fundamental mechanisms by which tin-based alloys enhance lithium ion transport and stabilize the interface, offering a robust theoretical foundation that complements the empirical results. This synergy between experimental innovation and computational science exemplifies the modern approach to materials research, where predictive modeling helps guide material design for superior battery performance.

The broader impact of this study extends into multiple strategic industrial sectors. Dr. Nam Ki-Hun emphasized the dual achievement of scalability and interfacial stability—both critical prerequisites for transitioning ASSBs from the laboratory to mass production. The modular thin-film interlayer concept is expected to be adaptable to large-scale manufacturing processes, paving the way for its application in electric vehicles, humanoid robotics, and energy storage systems (ESS). As these sectors demand batteries that combine safety, high energy density, and durability, KERI’s technology could become a cornerstone enabling next-generation electric mobility and smart technologies.

Moreover, the joint leadership in this study, including Dr. Ha Yoon-Cheol, highlighted the significance of this breakthrough in a highly competitive global context. As countries vie for supremacy in battery technology, the development of practical and scalable ASSB solutions provides a strategic competitive advantage. By securing intellectual property and advancing scientific knowledge, KERI is positioning South Korea as a key player in the future battery ecosystem. The research not only contributes to scientific progress but also aligns with national priorities in clean energy and technology sovereignty.

The research achievement is documented in a front cover article in the prestigious journal Advanced Energy Materials, an outlet with a substantial impact factor of 26.0 and recognized globally for publishing cutting-edge energy materials research. The publication, titled “Interface Stabilization via In Situ Lithiated Sn Interlayer in All-Solid-State Li-Metal Batteries: Toward Pellet-Type Cell to Pouch-Type Cell,” lays out the full technical details and experimental verification of the nano-Sn interlayer approach. This visibility underscores the scientific community’s recognition and the transformative potential of the innovation.

Supporting the core research efforts are the contributions from co-first authors Kim Garam and Im So-Jeong, emphasizing the collaborative nature of this achievement across academic and institutional boundaries, including the joint program between KERI and Changwon National University. The technology’s readiness for commercial exploitation is evidenced by the completion of a domestic patent application, safeguarding the innovation and opening pathways for future industry partnerships and commercialization strategies.

The research received targeted funding and support from KERI’s internal research programs and the Global Top Strategy Research Initiative (GT-3) under the Ministry of Science and ICT. These resources were crucial in enabling multidisciplinary research combining experimental development, theoretical calculation, and engineering validation. The intertwining of multiple research pillars illustrates the complexity and ambition involved in realizing high-performance all-solid-state batteries that could one day power everything from electric vehicles to grid-scale energy storage.

In sum, KERI’s nano-tin interlayer control technology marks a formidable advance in overcoming the interfacial challenges that have long bottlenecked the advancement of all-solid-state lithium metal batteries. By integrating material innovation, scalable manufacturing techniques, and computational insights, the research unlocks a clearer pathway toward the widespread adoption of ASSBs in next-generation power applications. This development not only enhances battery safety and energy density but also aligns with global efforts to embrace sustainable, high-efficiency energy storage systems essential for the clean energy transition.

Subject of Research: Development of nano-tin interlayer technology for interface stabilization in all-solid-state lithium metal batteries.

Article Title: Interface Stabilization via In Situ Lithiated Sn Interlayer in All-Solid-State Li-Metal Batteries: Toward Pellet-Type Cell to Pouch-Type Cell

News Publication Date: 1-Apr-2026

Web References: DOI link

Image Credits: Korea Electrotechnology Research Institute

Keywords

All-solid-state batteries, nano-tin interlayer, lithium metal anode, solid electrolyte, interface stabilization, dendrite suppression, energy density, battery safety, transfer printing, first-principles simulations, lithium ion transport, electric vehicle batteries