A1 Refereed original research article in a scientific journal
Process-dependent phase evolution in thermally sprayed Li4Ti5O12 thin-film anodes revealed by synchrotron and surface analysis; 
Authors: Hasani, Arman; Salminen, Antti; Joshi, Shrikant; Makowska, Malgorzata Grazyna; Chameh, Behnam; Lehto, Vesa-Pekka; Gidla, Vinay; Goel, Sneha; Angervo, Ilari; Ganvir, Ashish
Publisher: Elsevier BV
Publication year: 2026
Journal: Materials and Design
Article number: 116414
Volume: 267
ISSN: 0264-1275
eISSN: 1873-4197
DOI: https://doi.org/10.1016/j.matdes.2026.116414
Publication's open availability at the time of reporting: Open Access
Publication channel's open availability : Open Access publication channel
Web address : https://doi.org/10.1016/j.matdes.2026.116414
Self-archived copy’s web address: https://research.utu.fi/converis/portal/detail/Publication/526969572
Self-archived copy's licence: CC BY
Self-archived copy's version: Publisher`s PDF
Understanding process-induced phase evolution in thermally sprayed Li4Ti5O12 (LTO) thin-films is critical for developing scalable battery electrodes with stable electrochemical performance. This study comparatively investigates Atmospheric Plasma Spraying (APS), Suspension Plasma Spraying (SPS), and High-Velocity Oxy-Fuel (HVOF) processing of LTO thin-film anodes using SEM/EDS, laboratory XRD, synchrotron µXRD/µXRF mapping, XPS, and electrochemical characterization. Synchrotron µXRD revealed distinct process-dependent phase evolution governed by thermal exposure and quenching behavior. HVOF retained the highest spinel LTO fraction (66.8 %), APS retained 65.1 %, while SPS showed the strongest decomposition with only 53.5 % LTO together with increased Li2TiO3 (43.5 %) and TiO2 formation (3.0 %). XPS analysis identified Li2CO3 surface formation in APS and HVOF coatings, whereas SPS exhibited strong surface lithium depletion. Electrochemical measurements showed that APS-LTO exhibited the most favorable electrochemical response, with a working voltage of ∼1.56 V vs. Li/Li+ and lower polarization resistance (∼18.7 kΩ) compared with SPS and HVOF coatings. The results establish process–structure–property relationships linking thermal spray conditions with lithium retention, phase stability, and electrochemical behavior in thermally sprayed LTO thin-films.
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Funding information in the publication:
This research was supported by the GREEN-BAT project (2022–2025) under the M-ERA.Net framework. The authors acknowledge funding from the Research Council of Finland, M-ERA.NET 3 through the European Commission, and the national and regional financiers in Germany and Sweden. Prof. Ashish Ganvir acknowledges the SOLACE (DNR 360540) Academy research fellowship, funded by the Research Council of Finland and also extends his gratitude to the City of Turku for supporting his tenure-track grant. The work in Sweden, carried out at University West, received additional support from the NovelCABs proof-of-concept project, funded by the Swedish Energy Agency (Energimyndigheten, Dnr 2021-002227), and from Vinnova, the Swedish Governmental Agency for Innovation Systems, within the M-ERA.NET 3 GREEN-BAT initiative. This project has also received funding from the European Union’s Horizon 2020 research and innovation programme under grant agreement No 958174.The authors also acknowledge the Finnish Digital Design and Manufacturing Infrastructure (FiDiEm) infrastructure for access to the experimental facilities.
