Development of Lithium Cobalt Oxide (LCO) Coatings via Solution Precursor High Velocity Oxygen Fuel Method: An Integrated Experimental and Numerical Approach

In this study, lithium cobalt oxide (LCO) coatings were developed using the solution precursor high velocity oxygen fuel (SP-HVOF) technique. LCO is widely used in various applications, with its primary role as a cathode material in both conventional and solid-state batteries. A precursor solution, prepared by dissolving lithium nitrate and cobalt nitrate hydrate in water, was utilized for coating deposition. The research adopts a dual experimental and numerical approach. Experimentally, the impact of stand-off distance and spray parameters, such as oxidant-to-fuel ratio, on the coating microstructure and phase formation was investigated. The deposited coatings underwent heat treatment, phase analysis, and microstructural characterization, with results demonstrating a high yield of the LCO phase, highlighting the efficacy of SP-HVOF for producing high-quality cathode coatings. Additionally, computational fluid dynamics (CFD) simulations were conducted to analyze how variations in stand-off distance and spray parameters influence droplet and particle size, as well as temperature and velocity values along the flame and upon impact with the substrate. These simulations provide deeper insights into the dynamics of the process, offering guidance for optimizing deposition parameters to achieve superior coating performance. This comprehensive methodology contributes to advancements in LCO cathode coatings for battery technology.