Gm Global Technolgoy Operations, Inc.

The Penn State Research Foundation

Zhongyi Liu

Xiaosong Huang

Anil Kumar Sachdev

Bradley R Frieberg

James R Salvador

Michael Kevin Carpenter

Ratandeep S Kukreja

Daad B Haddad

Mei Cai

Xingcheng Xiao

Bin Hu

Tyson W Brown

Qiangfeng Xiao

Tengjiao Qi

Heewook Lee

Zhiqiang Yu

Frederick E Pinkerton

Junliang Zhang

Mark William Verbrugge

Hamid Ghavami Kia

Michael P Balogh

Li Yang

Wayne Cai

Anne M Dailly

Hongliang Wang

Ingrid A Rousseau

Frederick T Wagner

Michael J Lukitsch

Nicole D Ellison

Xingyi Yang

Julie A Swartz

Matthew Timothy Hamilton

Nicholas P Irish

Yan Wu

Junghyun Kim

Nannan Chen

James R Salavador

A brake drum having a composite structure includes a cylindrical body defining an inner friction surface and an outer surface. The cylindrical body includes a drum core comprising an Al—Si alloy, the drum core including an inner surface, and an outer surface of the drum core defining the outer surface of cylindrical body. The cylindrical body includes a thermal barrier layer comprising a thermally insulating material on the inner surface of the drum core, and a wear-resistant layer comprising an Fe—Al—Si—Zr alloy on the inner surface of the drum core over the thermal barrier layer, the wear-resistant layer defining the inner friction surface of the cylindrical body.

Composite brake drum

A method of manufacturing a brake rotor or brake drum having a composite structure includes casting an aluminum alloy to form a core of the brake rotor or brake drum, the core defining a core surface, depositing a high entropy alloy or yttrium stabilized zirconia on the core surface to form a thermal barrier layer on the core surface, and depositing an iron-aluminum-silicon-zirconium alloy on the thermal barrier layer to form a wear-resistant layer on the thermal barrier layer, the wear-resistant layer defining a friction surface of the brake rotor or brake drum.

Methods of producing composite vehicle braking components including aluminum alloys

Methods for forming prelithiated electroactive materials are provided. Methods include preparing a precursor that includes lithium and silicon and centrifugally distributing the precursor using a centrifugal atomizing reactor. Methods for preparing the precursor include contacting a first mixture including lithium and having a first temperature and a second mixture including silicon and having a second temperature in a mixing chamber to form a precursor. The first mixture and the second mixture each enters the mixing chamber at a pressure greater than or equal to about 10 PSI. The second temperature is greater than the first temperature. Centrifugally distributing the precursor includes contacting the precursor with a rotating surface in a centrifugal atomizing reactor and solidifying the precursor to form a plurality of substantially round solid electroactive particles including lithium and silicon and having D50 diameters of less than or equal to about 30 micrometers.

Methods of forming lithium-silicon alloys for electrochemical cells

A brake rotor having a composite structure may include an annular body defining opposite friction surfaces of the brake rotor. The annular body may include a core made of an Al—Si alloy, a thermal barrier layer made of a thermally insulating material disposed on the core, and a wear-resistant layer made of an Fe—Al—Si—Zr alloy disposed on the core over the thermal barrier layer. The wear-resistant layer may define a first one of the opposite friction surfaces of the annular body.

Composite brake rotor

A method of making a negative electrode for an electrochemical cell of a secondary lithium battery. The negative electrode includes composite Li—Si alloy particles dispersed in a polymer binder. The composite Li—Si alloy particles are formed by contacting Li—Si alloy particles with a precursor solution that includes a phosphorus sulfide compound dissolved in an organic solvent to form a lithium thiophosphate solid electrolyte layer over an entire outer surface of each of the Li—Si alloy particles.

Prelithiated negative electrodes including composite Li—Si alloy particles and methods of manufacturing the same

In a method of making a negative electrode for an electrochemical cell of a secondary lithium battery, a precursor mixture is prepared that includes electrochemically active Li&#x2014;Si alloy particles, electrically conductive carbon particles, and an inert polymer binder dissolved in a nonpolar organic solvent.

Prelithiated negative electrodes including Li&#x2014;Si alloy particles and methods of manufacturing the same

The present disclosure provides a method of making a negative electrode material for an electrochemical cell that cycles lithium ions. The method includes centrifugally distributing a precursor including silicon, lithium, and an additional metal (M) selected from the group consisting of: aluminum (Al), chromium (Cr), titanium (Ti), niobium (Nb), molybdenum (Mo), zirconium (Zr), yttrium (Y), cerium (Ce), and combinations thereof by contacting the precursor with a rotating surface in a centrifugal atomizing reactor and solidifying the precursor to form a plurality of substantially round solid electroactive particles that include LiSiM, where x is greater than 0 to less than or equal to about 0.85 and y corresponds to a weight percent of M that is greater than or equal to 0.1 wt. % to less than or equal to about 10 wt. %.

Pre-lithiated silicon particles and methods of forming the same

Methods of making a negative electrode material for an electrochemical cell that cycles lithium ions is provided. The method may include centrifugally distributing a molten precursor comprising silicon, oxygen, and lithium by contacting the molten precursor with a rotating surface in a centrifugal atomizing reactor. The molten precursor is formed by combining lithium, silicon, and oxygen. For example, the precursor may be formed from a mixture comprising silicon dioxide (SiO), lithium oxide (LiO), and silicon (Si). The method may further include solidifying the molten precursor to form a plurality of substantially round solid electroactive particles comprising a mixture of lithium silicide (LiSi, where 0&#x3c;y&#x2264;4.4) and a lithium silicate (LiSiO) and having a D50 diameter of less than or equal to about 20 micrometers.

Methods of producing pre-lithiated silicon oxide electroactive materials comprising silicides and silicates

A method of making a lithiated silicon-based precursor material for a negative electrode material of an electrochemical cell that cycles lithium ions is provided. An admixture comprising a plurality of lithium particles and a plurality of silicon particles is briquetted by applying pressure of greater than or equal to about 10 MPa and applying heat at a temperature of less than or equal to about 180&#xb0; C. to form a precursor briquette. The briquette has lithium particles and silicon particles distributed in a matrix and has a porosity level of less than or equal to about 60% of the total volume of the precursor briquette. The briquetting is conducted in an environment having less than or equal to about 0.002% by weight of any oxygen-bearing species or nitrogen (N).

Methods of briquetting precursor materials for prelithiated silicon active materials

A multistage centrifugal atomizer comprises an outer shell that contains an inlet port and an outlet port and that encloses a tundish, a first inclined rotating surface and a second inclined rotating surface. The first inclined rotating surface is opposedly disposed to the second inclined rotating surface. The inlet is used to introduce a molten material into the multistage atomizer and the outlet is used to remove ultrafine particles having a D50 of less than 20 micrometers.

Article for producing ultra-fine powders and method of manufacture thereof

An aluminum-iron alloy for casting includes aluminum, iron, silicon, and niobium present in the aluminum-iron alloy in an amount according to formula (I): (AlFeSi)+x Nb, wherein x is from 0.25 parts by weight to 2.5 parts by weight based on 100 parts by weight of the aluminum-iron alloy. A method of forming a component including forming the aluminum-iron alloy is also described.

Aluminum alloy for casting and method of forming a component

System and method of manufacturing high-strength bonded metal sheets for a battery cell are provided. The method comprises providing a stackup comprising a first metal sheet and a second metal sheet. The first and second metal sheets are separated by a first coating layer. The first coating layer comprises nickel-phosphide. The first metal sheet includes a first material of a first melting point and the second metal sheet includes a second material of a second melting point. The first coating layer including a third material of a third melting point. The method further comprises heating the stackup to allow crystallization of nickel in the first coating layer and remove the residual nickel-phosphide defining an enhanced coating layer. The enhanced coating layer comprises crystallized nickel for high-strength solid state bonding of the first and second metal sheets to the enhanced coating layer.

System and method for manufacturing high-strength bonded metal sheets for a battery cell

A method of making a negative electrode material for an electrochemical cell that cycles lithium ions is provided that includes centrifugally distributing a molten precursor comprising silicon and lithium by contacting the molten precursor with a rotating surface in a centrifugal atomizing reactor. The molten precursor is solidified to form a plurality of substantially round solid electroactive particles comprising an alloy of lithium and silicon and having a D50 diameter of less than or equal to about 20 micrometers. In certain variations, the negative electroactive material particles may further have one or more coatings disposed thereon, such as a carbonaceous coating and/or an oxide-based coating.

Methods of forming prelithiated silicon alloy electroactive materials

In an embodiment, a high temperature component comprises an aluminum iron alloy. The aluminum iron alloy comprises 52 to 61 atomic percent of aluminum based on the total atoms of aluminum and iron and comprises a first, B2 phase comprising FeAl and a second, triclinic phase comprising FeAl. The aluminum iron alloy can comprise an additional element, for example, at least one of silicon or zirconium.

Aluminum iron alloy having at least two phases

A lithium ion battery including an electrolyte and a lithium titanate negative electrode is provided. The lithium titanate negative electrode includes structures of a lithium titanate core and a conformal layer surrounding each lithium titanate core. The conformal layer either includes titanium oxide with substantially no lithium or has a concentration of lithium ranging from a lower concentration at a surface portion of the layer to a higher concentration at an interior portion of the layer adjacent to the lithium titanate core. A method of preparing the lithium titanate structures and a method of preparing an electrode for a lithium ion battery, wherein the electrode includes lithium titanate structures, are also provided.

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Troy, MI, United States of America

Zhongyi Liu