A1 Refereed original research article in a scientific journal
Laser post-processing as a surface engineering strategy for atmospheric plasma-sprayed thin-film all-solid-state battery components
Authors: Hasani, Arman; Nayak, Chinmayee; Vinay, Gidla; Salminen, Antti; Joshi, Shrikant; Goel, Sneha; Gopal, Vasanth; Mäkilä, Ermei; Juan, Mathias; Ganvir, Ashish
Publisher: Elsevier BV
Publication year: 2026
Journal: Applied Surface Science
Article number: 166624
Volume: 735
ISSN: 0169-4332
eISSN: 1873-5584
DOI: https://doi.org/10.1016/j.apsusc.2026.166624
Publication's open availability at the time of reporting: Open Access
Publication channel's open availability : Partially Open Access publication channel
Web address : https://doi.org/10.1016/j.apsusc.2026.166624
Self-archived copy’s web address: https://research.utu.fi/converis/portal/detail/Publication/523217654
Self-archived copy's licence: CC BY
Self-archived copy's version: Publisher`s PDF
The present study investigates laser post-processing as a method to tailor the surface properties of atmospheric plasma-sprayed (APS) anodes, solid electrolytes (SEs), and their half-cell configurations for all-solid-state batteries (ASSBs). Li4Ti5O12 (LTO) was used as the anode material, Li7La3Zr2O12 (LLZO) as the solid electrolyte, and aluminum as the substrate. APS was successfully employed to deposit single-layer LTO and LLZO thin films, as well as a double-layer LTO–LLZO half-cell configuration. XRD analysis showed that the as-sprayed LTO and LLZO coatings retained their characteristic crystalline phases without significant structural changes. Pulsed laser post-processing enabled effective surface smoothing of the plasma-sprayed ASSB components, while also inducing material remelting, partial ablation, and architecture-dependent effects. Single-layer and multilayer configurations responded differently due to variations in melting point, optical absorption, and heat flow pathways. Microstructural and elemental analyses using SEM/EDS and optical profilometry were conducted to evaluate the influence of laser surface modification. In addition, XPS confirmed that no changes in chemical state occurred between the as-sprayed and laser-processed LLZO coatings. Overall, this proof-of-concept study demonstrates the potential of laser post-processing to improve the surface quality of APS-sprayed ASSB components and provides useful insights for battery manufacturing and thermal spray communities.
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Funding information in the publication:
The Authors acknowledges financial support from GREEN-BAT (352517), co-funded by the Research Council of Finland and the European Union under the M-ERA.NET 2021 framework, as well as the SOLACE (DNR 360540) Academy research fellowship, funded by the Research Council of Finland. Prof. Ashish Ganvir also extends his gratitude to the City of Turku for supporting his tenure-track grant. Prof. Antti Salminen acknowledges financial support through the DREAMS TENK TOT project (5159/31/2021), funded by Business Finland. The authors also acknowledge the Finnish Digital Design and Manufacturing Infrastructure (FiDiEm) for access to the experimental facilities. The Swedish portion of this research, conducted at University West, Sweden, was funded by the following projects: (a) the proof-of-concept project NovelCABs, supported by the Swedish Energy Agency (Energimyndigheten, Dnr 2021-002227), and (b) the transnational M-ERA.NET 3 project GREEN-BAT, with backing from the European Commission, with Vinnova (the Swedish Governmental Agency for Innovation Systems) as the national financier for Swedish participation. This project has received funding from the European Union’s Horizon 2020 research and innovation program under grant agreement No 958174.
