This thesis explores mechanical behavior of microelectronic devices and lithium-ion batteries. We first examine electromigration-induced void formation in solder bumps by constructing a theory that couples electromigration and creep. The theory can predict the critical current density below which voids do not form. Due to the effects of creep, this quantity is found to be independent of the solder size and decrease exponentially with increasing temperature, different from existing theories. / Engineering and Applied Sciences

Lithium ion batteries have become one of the most popular types of battery in consumer electronics as well as aerospace and automotive applications. The efficient use of Li-ion batteries in automotive applications requires well designed battery management systems. Low order Li-ion battery models that are fast and accurate are key to well- designed BMS. The control oriented low order physics based model developed previously cannot predict the temperature and predicts inaccurate voltage dynamics. This thesis focuses on two things: (1) the development of a thermal component to the isothermal model and (2) the development of a hybrid neural net and physics based battery model that corrects the output of the physics based model. A simple first law based thermal component to predict the temperature model is implemented. The thermal model offers a reasonable approximation of the temperature dynamics of the battery discharge over a wide operating range, for both a well-ventilated battery as well as an insulated battery. The model gives an accurate prediction of temperature at higher SOC, but the accuracy drops sharply at lower SOCs. This possibly is due to a local heat generation term that dominates heat generation at lower SOCs. A neural net based modeling approach is used to compensate for the lack of knowledge of material parameters of the battery cell in the existing physics based model. This model implements a neural net that corrects the voltage output of the model and adds a temperature prediction sub-network. Given the knowledge of the physics of the battery, sparse neural nets are used. Multiple types of standalone neural nets as well as hybrid neural net and physics based battery models are developed and tested to determine the appropriate configuration for optimal performance. The prediction of the neural nets in ventilated, insulated and stressed conditions was compared to the actual outputs of the batteries. The modeling approach presented here is able to accurately predict voltage output of the battery for multiple current profiles. The temperature prediction of the neural nets in the case of the ventilated batteries was harder to predict since the environment of the battery was not controlled. The temperature predictions in the insulated cases were quite accurate. The neural nets are trained, tested and validated using test data from a 4.4Ah Boston Power lithium ion battery cell. / text

The layered transition metal oxide composition series of Li1+xV1-xO2 was synthesized using the solid state synthesis technique. X-ray diffraction was used to determine the dependence of structure on composition and clearly indicated a structural anomaly at x = 0 caused by the unusual magnetic ordering on the triangular lattice of the V3+ layer. To prevent magnetic frustration V3+ cations undergo orbital ordering and subsequent periodic displacent to form “trimers”. The periodicity of this phenomena results in a superlattice structure that can be observed as a faint peak in XRD spectra. The relationship between composition, superlattice peak intensity and lattice parameters was clearly documented for the first time. Li/Li1+xV1-xO2 cells were made and tested. Recent literature has shown that the transformation to 1T Li2VO2 upon lithiation is dependant on a nonzero x (ideally x = 0.07 for maximum capacity) to make a small number of tetrahedrally coordinated Li sites accessible. These sites then act as a trigger for shearing into the 1T phase. The cells described within this work intercalated significant amounts of lithium at a higher potential than the to 1T transition, possibly signifying occupation of a large number of the tetrahedral sites. LiVO2 is known to undergo delithiation even in ambient conditons and this can lead to cationic disorder. Cationic disorder is an inhibitor of anion sheet shearing and this suggests that sample handling could be a cause of the observed electrochemical behaviour. The effects of air and water exposure were investigated.

Lithium ion batteries (LIBs) play an essential role in modern life. Although relatively unknown throughout past decades, LIBs have supplanted several categories of chemically rechargeable batteries including lead-acid, nickel-cadmium and nickel-hydrogen batteries. Nowadays, LIBs dominate the market of portable electronic devices such as mobile phones, digital cameras and laptops. As the price of petroleum keeps increasing, electrically powered or assisted vehicles using LIBs are similarly gaining in the automotive market. However, current state-of-art LIBs using graphite as their electrical anode and Li metal oxides as the cathode are facing major challenges. For example, the current LIBs are approaching their capacity limit. Batteries that can maintain high charge and discharge rates are in great demand, which has not been adequately addressed by modern LIBs. Safety issues with these current batteries are being reported even from some market leaders such as Boeing and Tesla. Herein, several categories of novel anode materials have been investigated in a search for promising candidates to enable evolution of the next generation of lithium ion batteries. This research included silicon-carbon based materials, especially silicon-graphene (Si-G) materials and their derivatives, and transitional metal based materials, e.g., cobalt oxide (Co3O4). In this proposed work, Si-G composites were synthesized via a freeze-drying method; the conditions of the synthesis were controlled and adjusted to obtain a Si-G composite with the most promising morphology as well as battery performance. Based on preliminary results, graphene wrapped silicon electrodes showed significantly improved cycling performance than bare silicon electrodes. At high charge and discharge rates it was found that Si-G composites also showed superior stability and capacity retention over bare silicon electrodes. After 200 cycles, the optimized Si-G composite maintained a capacity retention close to 100%, with a capacity of 800 mAh g-1 at a 0.2 C rate and 600 mAh g-1 at a 1 C rate. This observation was a prominent increase from the performance of commercial graphite-based batteries at a theoretical capacity 372 mAh g-1. Considering the facile fabrication method and increasing use of commercial silicon nano-particles (Si-NPs) into account, Si-G composites could be a promising candidate for the anode material in LIBs. Extended work on the Si-G project also involved further decorations based on the Si-G composite synthesized from the method previously mentioned, as well as improvement on the synthesis method to make it more applicable for industrial purposes. Cobalt Oxide (Co3O4), a transitional metal oxide which has a theoretical capacity of 890 mAh g-1, draws attention as an anode material in LIBs due to its capacity compared to graphite and heavily reduced degradation compared to silicon. A novel electrode fabrication procedure was adopted in this research together with a simple material-synthesizing methodology. Similar to common silicon electrodes, Co3O4 suffers from poor electron conductivity volume change upon cycling. Herein the Co3O4 active material is directly deposited on stainless steel mesh, serving as both a current collector and a substrate for the active material. Through adapting the electrode fabrication process by directly depositing on the stainless steel electron conductor, the traditional conductive carbon material and binder requirements can be avoided. As a result, the process is reduced in both cost and complexity. The presented novel electrode design facilitates both ion diffusion and electron transportation, improving the overall performance of the material in LIBs. After 100 cycles of charge and discharge, Co3O4 on stainless steel mesh shows a capacity around 770 mAh g-1, which is more than twice that of graphite. The capacity retention was around 90% in this case.

Rechargeable lithium sulfur (Li-S) batteries are potentially safe, environmentally friendly and economical alternative energy storage systems that can potentially be combined with renewable sources including wind solar and wave energy. Sulfur has a high theoretical specific capacity of ~1680 mAh/g, attainable through the reversible redox reaction denoted as S8+16Li ↔8Li¬2S, which yields an average cell voltage of ~2.2 V. However, two detrimental factors prevent the achievement of the full potential of the Li-S batteries. First, the poor electrical/ionic conductivity of elemental sulfur and Li2S severely hampers the utilization of active material. Second, dissolution of intermediate long-chain polysulfides (Li2Sn, 2<n<7) into the electrolyte and their shuttle between cathode and anode lead to fast capacity degradation and low Coulombic efficiency. As a result of this shuttle process, insoluble and insulating Li2S/Li2S2 precipitate on the surface of electrodes causing loss of active material and rendering the electrode surface electrochemically inactive. Extensive research efforts have been devoted to overcome the aforementioned problems, such as combination of sulfur with conductive polymers, and encapsulation or coating of elemental sulfur in different nanostructured carbonaceous materials. Noteworthy, sulfur-polyacrylonitrile (SPAN) composites, wherein sulfur is chemically bond to the polymer backbone and PAN acts as a conducting matrix, have shown some success in suppressing the shuttle effect. However, due to the limited electrical conductivity of polyacrylonitrile, the capacity retention and rate performance of the SPAN systems are still very modest, which shows only 67 % retention of the initial capacity after 50 cycles for the binary system. Recently, graphene has been intensively investigated for enhancing the rate and cycling performance of lithium sulfur batteries. Graphene, which has a two-dimensional, one-atom-thick nanosheet structure, offers extraordinary electronic, thermal and mechanical properties. Herein, a sulfur-polyacrylonitrile/reduced graphene oxide (SPAN/RGO) composite with unique electrochemical properties was prepared. PAN is deposited on the surface of RGO sheets followed by ball milling with sulfur and heat treatment. Infrared spectroscopy and microscopy studies indicate that the composite consists of RGO decorated with SPAN particles of 100 nm average size. The PAN/RGO composite shows good overall electrochemical performance when used in Li/S batteries. It exhibits ~85% retention of the initial reversible capacity of 1467 mAh/g over 100 cycles at a constant current rate of 0.1 C and retains 1100 mAh/g after 200 cycles. In addition, the composite displays excellent Coulombic efficiency and rate capability, delivering up to 828 mAh/g reversible capacity at 2 C. The improved performance stems from composition and structure of the composite, wherein RGO renders a robust electron transport framework and PAN acts as sulfur/polysulfide absorber.

Rechargeable lithium sulfur (Li-S) batteries are potentially safe, environmentally friendly and economical alternative energy storage systems that can potentially be combined with renewable sources including wind solar and wave energy. Sulfur has a high theoretical specific capacity of ~1680 mAh/g, attainable through the reversible redox reaction denoted as S8+16Li ↔8Li¬2S, which yields an average cell voltage of ~2.2 V. However, two detrimental factors prevent the achievement of the full potential of the Li-S batteries. First, the poor electrical/ionic conductivity of elemental sulfur and Li2S severely hampers the utilization of active material. Second, dissolution of intermediate long-chain polysulfides (Li2Sn, 2<n<7) into the electrolyte and their shuttle between cathode and anode lead to fast capacity degradation and low Coulombic efficiency. As a result of this shuttle process, insoluble and insulating Li2S/Li2S2 precipitate on the surface of electrodes causing loss of active material and rendering the electrode surface electrochemically inactive. Extensive research efforts have been devoted to overcome the aforementioned problems, such as combination of sulfur with conductive polymers, and encapsulation or coating of elemental sulfur in different nanostructured carbonaceous materials. Noteworthy, sulfur-polyacrylonitrile (SPAN) composites, wherein sulfur is chemically bond to the polymer backbone and PAN acts as a conducting matrix, have shown some success in suppressing the shuttle effect. However, due to the limited electrical conductivity of polyacrylonitrile, the capacity retention and rate performance of the SPAN systems are still very modest, which shows only 67 % retention of the initial capacity after 50 cycles for the binary system. Recently, graphene has been intensively investigated for enhancing the rate and cycling performance of lithium sulfur batteries. Graphene, which has a two-dimensional, one-atom-thick nanosheet structure, offers extraordinary electronic, thermal and mechanical properties. Herein, a sulfur-polyacrylonitrile/reduced graphene oxide (SPAN/RGO) composite with unique electrochemical properties was prepared. PAN is deposited on the surface of RGO sheets followed by ball milling with sulfur and heat treatment. Infrared spectroscopy and microscopy studies indicate that the composite consists of RGO decorated with SPAN particles of 100 nm average size. The PAN/RGO composite shows good overall electrochemical performance when used in Li/S batteries. It exhibits ~85% retention of the initial reversible capacity of 1467 mAh/g over 100 cycles at a constant current rate of 0.1 C and retains 1100 mAh/g after 200 cycles. In addition, the composite displays excellent Coulombic efficiency and rate capability, delivering up to 828 mAh/g reversible capacity at 2 C. The improved performance stems from composition and structure of the composite, wherein RGO renders a robust electron transport framework and PAN acts as sulfur/polysulfide absorber.

abstract: Lithium ion batteries have emerged as the most popular energy storage system, but they pose safety issues under extreme temperatures or in the event of a thermal runaway. Lithium ion batteries with inorganic separators offer the advantage of safer operation. An inorganic separator for lithium ion battery was prepared by an improved method of blade coating α-Al2O3 slurry directly on the electrode followed by drying. The improved separator preparation involves a twice-coating process instead of coating the slurry all at once in order to obtain a thin (~40 µm) and uniform coat. It was also found that α-Al2O3 powder with particle size greater than the pore size in the electrode is preferable for obtaining a separator with 40 µm thickness and consistent cell performance. Unlike state-of-the-art polyolefin separators such as polypropylene (PP) which are selectively wettable with only certain electrolytes, the excellent electrolyte solvent wettability of α-Al2O3 allows the coated alumina separator to function with different electrolytes. The coated α-Al2O3 separator has a much higher resistance to temperature effects than its polyolefin counterparts, retaining its dimensional integrity at temperatures as high as 200ºC. This eliminates the possibility of a short circuit during thermal runaway. Lithium ion batteries assembled as half-cells and full cells with coated α-Al2O3 separator exhibit electrochemical performance comparable with that of polyolefin separators at room temperature. However, the cells with coated alumina separator shows better cycling performance under extreme temperatures in the temperature range of -30°C to 60°C. Therefore, the coated α-Al2O3 separator is very promising for application in safe lithium-ion batteries. / Dissertation/Thesis / Masters Thesis Chemical Engineering 2016

abstract: Plastic crystals as a class are of much interest in applications as solid state electrolytes for electrochemical energy conversion devices. A subclass exhibit very high protonic conductivity and its members have been investigated as possible fuel cell electrolytes, as first demonstrated by Haile’s group in 2001 with CsHSO4. To date these have been inorganic compounds with tetrahedral oxyanions carrying one or more protons, charge-balanced by large alkali cations. Above the rotator phase transition, the HXO4- anions re-orient at a rate dependent on temperature while the centers of mass remain ordered. The transition is accompanied by a conductivity "jump" (as much as four orders of magnitude, to ~ 10 mScm-1 in the now-classic case of CsHSO4) due to mobile protons. These superprotonic plastic crystals bring a “true solid state” alternative to polymer electrolytes, operating at mild temperatures (150-200ºC) without the requirement of humidification. This work describes a new class of solid acids based on silicon, which are of general interest. Its members have extraordinary conductivities, as high as 21.5 mS/cm at room temperature, orders of magnitude above any previous reported case. Three fuel cells are demonstrated, delivering current densities as high as 225 mA/cm2 at short-circuit at 130ºC in one example and 640 mA/cm2 at 87ºC in another. The new compounds are insoluble in water, and their remarkably high conductivities over a wide temperature range allow for lower temperature operations, thus reducing the risk of hydrogen sulfide formation and dehydration reactions. Additionally, plastic crystals have highly advantageous properties that permit their application as solid state electrolytes in lithium batteries. So far only doped materials have been presented. This work presents for the first time non-doped plastic crystals in which the lithium ions are integral part of the structure, as a solid state electrolyte. The new electrolytes have conductivities of 3 to 10 mS/cm at room temperature, and in one example maintain a highly conductive state at temperatures as low as -30oC. The malleability of the materials and single ion conducting properties make these materials highly interesting candidates as a novel class of solid state lithium conductors. / Dissertation/Thesis / Doctoral Dissertation Chemistry 2016

Doctor of Philosophy / Department of Chemistry / Jun Li / Electrical energy storage (EES) is crucial in todays’ society owing to the advances in electric cars, microelectronics, portable electronics and grid storage backup for renewable energy utilization. Lithium ion batteries (LIBs) have dominated the EES market owing to their wide use in portable electronics. Despite the success, low specific capacity and low power rates still need to be addressed to meet the increasing demands. Particularly, the low specific capacity of cathode materials is currently limiting the energy storage capability of LIBs. Vanadium pentoxide (V₂O₅) has been an emerging cathode material owing to its low cost, high electrode potential in lithium-extracted state (up to 4.0 V), and high specific capacities of 294 mAh g⁻¹ (for a 2 Li⁺/V₂O₅ insertion process) and 441 mAh g⁻¹ (for a 3 Li⁺/V₂O₅ insertion process). However, the low electrical conductivities and slow Li⁺ ion diffusion still limit the power rate of V₂O₅. To enhance the power-rate capability we construct two core-shell structures that can achieve stable 2 and 3 Li⁺ insertion at high rates. In the first approach, uniform coaxial V₂O₅ shells are coated onto electrospun carbon nanofiber (CNF) cores via pulsed electrodeposition. The materials analyses confirm that the V₂O₅ shell after 4 hours of thermal annealing at 300 °C is a partially hydrated amorphous structure. SEM and TEM images indicate that the uniform 30 to 50 nm thick V₂O₅ shell forms an intimate interface with the CNF core. Lithium insertion capacities up to 291 and 429 mAh g⁻¹ are achieved in the voltage ranges of 4.0 – 2.0 V and 4.0 – 1.5 V, respectively, which are in good agreement with the theoretical values for 2 and 3 Li⁺/V₂O₅ insertion. Moreover, after 100 cycles, remarkable retention rates of 97% and 70% are obtained for 2 and 3 Li⁺/V₂O₅ insertion, respectively. In the second approach, we implement a three-dimensional (3D) core-shell structure consisting of coaxial V₂O₅ shells sputter-coated on vertically aligned carbon nanofiber (VACNF) cores. The hydrated amorphous microporous structure in the “as-deposited” V₂O₅ shells and the particulated nano-crystalline V₂O₅ structure formed by thermal annealing are compared. The former provides remarkably high capacity of 360 and 547 mAh g⁻¹ in the voltage range of 4.0 – 2.0 V and 4.0 – 1.5 V, respectively, far exceeding the theoretical values for 2 and 3 Li⁺/V₂O₅ insertion, respectively. After 100 cycles of 3 Li⁺/V₂O₅ insertion/extraction at 0.20 A g⁻¹ (~ C/3), ~ 84% of the initial capacity is retained. After thermal annealing, the core-shell structure presents a capacity of 294 and 390 mAh g⁻¹, matching well with the theoretical values for 2 and 3 Li⁺/V₂O₅ insertion. The annealed sample shows further improved stability, with remarkable capacity retention of ~100% and ~88% for 2 and 3 Li⁺/V₂O₅ insertion/extraction. However, due to the high cost of Li. alternative approaches are currently being pursued for large scale production. Sodium ion batteries (SIB) have been at the forefront of this endeavor. Here we investigate the sodium insertion in the hydrate amorphous V₂O₅ using the VACNF core-shell structure. Electrochemical characterization was carried out in the potential ranges of 3.5 – 1.0, 4.0 – 1.5, and 4.0 – 1.0 (vs Na/Na⁺). An insertion capacity of 196 mAh g-1 is achieved in the potential range of 3.5 – 1.0 V (vs Na/Na⁺) at a rate of 250 mA g⁻¹. When the potential window is shifted upwards to 4.0 – 1.5 V (vs Na/Na⁺) an insertion capacity of 145 mAh g⁻¹ is achieved. Moreover, a coulombic efficiency of ~98% is attained at a rate of 1500 mA g⁻¹. To enhance the energy density of the VACNF-V₂O₅ core-shell structures, the potential window is expanded to 4.0 – 1.0 V (vs Na/Na⁺) which achieved an initial insertion capacity of 277 mAh g⁻¹. The results demonstrate that amorphous V₂O₅ could serve as a cathode material in future SIBs.

abstract: Life cycle assessment (LCA) is a powerful framework for environmental decision making because the broad boundaries called for prevent shifting of burden from one life-cycle phase to another. Numerous experts and policy setting organizations call for the application of LCA to developing nanotechnologies. Early application of LCA to nanotechnology may identify environmentally problematic processes and supply chain components before large investments contribute to technology lock in, and thereby promote integration of environmental concerns into technology development and scale-up (enviro-technical integration). However, application of LCA to nanotechnology is problematic due to limitations in LCA methods (e.g., reliance on data from existing industries at scale, ambiguity regarding proper boundary selection), and because social drivers of technology development and environmental preservation are not identified in LCA. This thesis proposes two methodological advances that augment current capabilities of LCA by incorporating knowledge from technical and social domains. Specifically, this thesis advances the capacity for LCA to yield enviro-technical integration through inclusion of scenario development, thermodynamic modeling, and use-phase performance bounding to overcome the paucity of data describing emerging nanotechnologies. With regard to socio-technical integration, this thesis demonstrates that social values are implicit in LCA, and explores the extent to which these values impact LCA practice and results. There are numerous paths of entry through which social values are contained in LCA, for example functional unit selection, impact category selection, and system boundary definition - decisions which embody particular values and determine LCA results. Explicit identification of how social values are embedded in LCA promotes integration of social and environmental concerns into technology development (socio-enviro-technical integration), and may contribute to the development of socially-responsive and environmentally preferable nanotechnologies. In this way, tailoring LCA to promote socio-enviro-technical integration is a tangible and meaningful step towards responsible innovation processes. / Dissertation/Thesis / M.S. Engineering 2013