Iron Could Revolutionize Greener, Cheaper Lithium-Ion Batteries, Research Finds

What if a common element could replace scarce, expensive ones in electric car batteries?

A collaboration co-led by an Oregon State University chemistry researcher aims to ignite a green battery revolution by demonstrating that iron, instead of cobalt and nickel, can be used as a cathode material in lithium-ion batteries.

The findings, published today in Science Advances, hold significant implications, according to Oregon State's Xiulei "David" Ji.

"We've transformed the reactivity of iron metal, the cheapest metal commodity," Ji said. "Our electrode can offer a higher energy density than the state-of-the-art cathode materials in electric vehicles. And since we use iron, which costs less than a dollar per kilogram—a small fraction of the cost of nickel and cobalt, which are indispensable in current high-energy lithium-ion batteries—the cost of our batteries is potentially much lower."

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Currently, the cathode accounts for 50% of the cost of manufacturing a lithium-ion battery cell. Beyond economic benefits, iron-based cathodes also promise greater safety and sustainability.

With the increasing production of lithium-ion batteries to support the electrification of the transportation sector, global demand for nickel and cobalt has surged. Ji points out that anticipated shortages of nickel and cobalt in the coming decades could severely limit battery production if current methods remain unchanged.