A review of profiling the dynamic interfaces in lithium-ion batteries via multiscale methods
Tao Geng , Qingquan Wang , Na Li , Siqi Lyu , Qi Wang , Dongbai Sun , Haosen Chen , Weili Song
International Journal of Minerals, Metallurgy and Materials ›› 2026, Vol. 33 ›› Issue (8) : 2498 -2526.
Owing to their high energy and power densities, lithium-ion batteries are widely recognized as fundamental components of modern electrochemical energy storage systems for electric vehicles and grid-scale energy storage. However, long-term stability and intrinsic safety remain critical challenges that limit commercial deployment. Increasing evidence indicates that battery degradation and severe failure events are closely associated with the evolution of internal dynamic interfaces. This review establishes a full lifecycle, multiscale framework for dynamic interface evolution in lithium-ion batteries, explicitly linking nanoscale interfacial chemistry, mesoscale structural and transport heterogeneity, macroscale performance degradation, and safety failures. By correlating cross-scale interface dynamics with battery aging and thermal runaway behavior, this study provides an integrated mechanistic foundation for advanced diagnostics, modeling, and early warning strategies.
dynamic interface / interface modulation / lithium plating / life stage / lithium-ion battery / profiling methods
| [1] |
H.S. Liu, Z. Xie, W. Qu, et al., High-voltage induced surface and intragranular structural evolution of Ni-rich layered cathode, Small, 18(2022), No. 19, art. No. 2200627. |
| [2] |
W.P. Diao, J. Kim, M.H. Azarian, and M. Pecht, Degradation modes and mechanisms analysis of lithium-ion batteries with knee points, Electrochim. Acta, 431(2022), art. No. 141143. |
| [3] |
|
| [4] |
|
| [5] |
|
| [6] |
Y. Lin, W.X. Hu, M.F. Ding, et al., Unveiling the three stages of Li plating and dynamic evolution processes in pouch C/LiFePO4 batteries, Adv. Energy Mater., 14(2024), No. 36, art. No. 2400894. |
| [7] |
|
| [8] |
S.K. Jung, H. Gwon, J. Hong, et al., Understanding the degradation mechanisms of LiNi0.5Co0.2Mn0.3O2 cathode material in lithium ion batteries, Adv. Energy Mater., 4(2014), No. 1, art. No. 1300787. |
| [9] |
P.F. Yan, J.M. Zheng, M. Gu, J. Xiao, J.G. Zhang, and C.M. Wang, Intragranular cracking as a critical barrier for high-voltage usage of layer-structured cathode for lithium-ion batteries, Nat. Commun., 8(2017), art. No. 14101. |
| [10] |
|
| [11] |
|
| [12] |
|
| [13] |
K. Shah, N. Balsara, S. Banerjee, et al., State of the art and future research needs for multiscale analysis of Li-ion cells, J. Electrochem. Energy Convers. Storage, 14(2017), No. 2, art. No. 020801. |
| [14] |
C. Leau, Y. Wang, C.G. Mouravieff, et al., Tracking solid electrolyte interphase dynamics using operando fibre-optic infra-red spectroscopy and multivariate curve regression, Nat. Commun., 16(2025), art. No. 757. |
| [15] |
E.G. Sukenik, L. Kasaei, and G.G. Amatucci, Impact of gradient porosity in ultrathick electrodes for lithium batteries, J. Power Sources, 579(2023), art. No. 233327. |
| [16] |
W.Y. Huang, J.Y. Li, Q.H. Zhao, et al., Mechanochemically robust LiCoO2 with ultrahigh capacity and prolonged cyclability, Adv. Mater., 36(2024), No. 32, art. No. 2405519. |
| [17] |
S. Zhang, Z. Yang, Y. Lu, W.W. Xie, Z.H. Yan, and J. Chen, Insights into cation migration and intermixing in advanced cathode materials for lithium-ion batteries, Adv. Energy Mater., 14(2024), No. 36, art. No. 2402068. |
| [18] |
|
| [19] |
|
| [20] |
|
| [21] |
|
| [22] |
Y.W. Mao, X.L. Wang, S.H. Xia, et al., High-voltage charging-induced strain, heterogeneity, and micro-cracks in secondary particles of a nickel-rich layered cathode material, Adv. Funct. Mater., 29(2019), No. 18, art. No. 1900247. |
| [23] |
|
| [24] |
W.X. Huang, Y.S. Ye, H. Chen, et al., Onboard early detection and mitigation of lithium plating in fast-charging batteries, Nat. Commun., 13(2022), No. 1, art. No. 7091. |
| [25] |
X. Li, L. Dai, L. Yang, et al., Promoting interfacial reaction via quantifying NMC811 CEI evolution and Li+ desolvation using single-particle electrochemical methods, Adv. Funct. Mater., 35(2025), No. 5, art. No. 2414550. |
| [26] |
|
| [27] |
|
| [28] |
Y.Q. Wang, R.W. Huang, J.Y. Hou, et al., In situ differential electrochemical mass spectrometry study on the effects of negative/positive ratios on gas evolution in lithium-ion full batteries, J. Energy Storage, 87(2024), art. No. 111414. |
| [29] |
W.S. Li, Review: An unpredictable hazard in lithium-ion batteries from transition metal ions: Dissolution from cathodes, deposition on anodes and elimination strategies, J. Electrochem. Soc., 167(2020), No. 9, art. No. 090514. |
| [30] |
X. Li, J. Huang, L. Yang, et al., Quantifying the electrochemical kinetics of battery positive-electrode crystal facets, Nat. Commun., 16(2025), art. No. 10229. |
| [31] |
X. Li, N. Li, L. Yang, H.S. Chen, and W.L. Song, Frontispiece: Single-particle measurements: A powerful method for investigating electrochemical reactions, Chem. Eur. J., 29(2023), No. 7, art. No. e202380763. |
| [32] |
M. Feinauer, A.A.A.E. Latif, P. Sichler, A.A. Regalado, M.W. Mehrens, and T. Waldmann, Change of safety by main aging mechanism-A multi-sensor accelerating rate calorimetry study with commercial Li-ion pouch cells, J. Power Sources, 570(2023), art. No. 233046. |
| [33] |
S.Q. Lyu, J. Yu, X.H. Guo, et al., Mechanistically understanding the correlation between dynamic interface variation and stability of surface coating on the NMC811 materials, Adv. Energy Mater., 15(2025), No. 5, art. No. 2403270. |
| [34] |
P.M. Attia, A. Bills, F.B. Planella, et al., Review: “Knees” in lithium-ion battery aging trajectories, J. Electrochem. Soc., 169(2022), No. 6, art. No. 060517. |
| [35] |
|
| [36] |
J. Keil and A. Jossen, Electrochemical modeling of linear and nonlinear aging of lithium-ion cells, J. Electrochem. Soc., 167(2020), No. 11, art. No. 110535. |
| [37] |
|
| [38] |
Y.D. Zhang, H. Wang, Z.Z. Li, et al., Innovative anode design to enhance both volumetric and gravimetric energy densities of LiCoO2 Graphite pouch cells, Adv. Energy Mater., 15(2025), No. 10, art. No. 2403804. |
| [39] |
|
| [40] |
|
| [41] |
Y. Tian, C. Lin, H.L. Li, J.Y. Du, and R. Xiong, Detecting undesired lithium plating on anodes for lithium-ion batteries–A review on the in-situ methods, Appl. Energy, 300(2021), art. No. 117386. |
| [42] |
Y. Fujihara and T. Kobayashi, Multiple knee points in the degradation of a commercial lithium-ion battery: A case study of the NCM/graphite system, Electrochemistry, 93(2025), No. 6, art. No. 063003. |
| [43] |
D.P. Finegan, M. Scheel, J.B. Robinson, et al., In-operando high-speed tomography of lithium-ion batteries during thermal runaway, Nat. Commun., 6(2015), art. No. 6924. |
| [44] |
Y.L. Han, Y.M. Zhao, A.J. Ming, et al., Application of an NDIR sensor system developed for early thermal runaway warning of automotive batteries, Energies, 16(2023), No. 9, art. No. 3620. |
| [45] |
|
| [46] |
W.X. Mei, Z. Liu, C.D. Wang, et al., Operando monitoring of thermal runaway in commercial lithium-ion cells via advanced lab-on-fiber technologies, Nat. Commun., 14(2023), art. No. 5251. |
| [47] |
X. Liu, L. Yin, D.S. Ren, et al., In situ observation of thermal-driven degradation and safety concerns of lithiated graphite anode, Nat. Commun., 12(2021), art. No. 4235. |
| [48] |
|
| [49] |
X. Li, N. Li, K.L. Zhang, et al., Correlating electrochemical kinetic parameters of single LiNi1/3Mn1/3Co1/3O2 particles with the performance of corresponding porous electrodes, Angew. Chem. Int. Ed., 61(2022), No. 34, art. No. e202205394. |
| [50] |
X. Zhang, N. Li, X. Li, L. Yang, W.L. Song, and Y.N. Wang, Single-particle measurement: A valuable method for studying structural evolution of battery and performance degradation, ChemElectroChem, 12(2025), No. 3, art. No. e202400529. |
| [51] |
Z.J. Liang, Y.H. Peng, X. Zhang, K.W. Cao, W. Xiao, and D. Gu, Sulfur-doped CMK-5 with expanded lattice for high-performance lithium ion batteries, Chin. Chem. Lett., 34(2023), No. 7, art. No. 108054. |
| [52] |
|
| [53] |
|
| [54] |
|
| [55] |
|
| [56] |
|
| [57] |
|
| [58] |
Y. Song, M.X. Zhou, Z. Chen, H.L. Nie, J.J. Shao, and G.M. Zhou, Integrated interconnected porous and lamellar structures realized fast ion/electron conductivity in high-performance lithium-sulfur batteries, Chin. Chem. Lett., 35(2024), No. 6, art. No. 109200. |
| [59] |
|
| [60] |
G.L. Zhu, C.Z. Zhao, J.Q. Huang, et al., Fast charging lithium batteries: Recent progress and future prospects, Small, 15(2019), No. 15, art. No. 1805389. |
| [61] |
|
| [62] |
L.L. Ju, X.N. Li, G.C. Geng, and Q.Y. Jiang, Degradation diagnosis of lithium-ion batteries considering internal gas evolution, J. Energy Storage, 71(2023), art. No. 108084. |
| [63] |
|
| [64] |
W.S. Huang, X.N. Feng, X.B. Han, W.F. Zhang, and F.C. Jiang, Questions and answers relating to lithium-ion battery safety issues, Cell Rep. Phys. Sci., 2(2021), No. 1, art. No. 100285. |
| [65] |
Z.X. Cheng, L.R. Ju, J.Y. Li, et al., Early warning of thermal runaway for larger-format lithium iron-phosphate battery by coupling internal pressure and temperature, Appl. Energy, 383(2025), art. No. 125396. |
| [66] |
C. Bommier, W. Chang, Y.F. Lu, et al., In operando acoustic detection of lithium metal plating in commercial LiCoO2/graphite pouch cells, Cell Rep. Phys. Sci., 1(2020), No. 4, art. No. 100035. |
| [67] |
|
| [68] |
|
| [69] |
Y. Ding, Y. Li, R.Y. Xu, et al., Cross-scale deciphering thermal failure process of Ni-rich layered cathode, Nano Energy, 126(2024), art. No. 109685. |
| [70] |
Y.D. Xin, J.H. Wei, S.L. Chen, et al., Quantifying the thermochemical stability of high-nickel LiNi0.9Mn0.05Co0.05 O2: Single-crystalline vs. polycrystalline, Electrochim. Acta, 533(2025), art. No. 146532. |
| [71] |
|
| [72] |
M.C. Liu, H.J. Chen, G. Wu, X.L. Wang, and Y.Z. Wang, Multifunctional robust aerogel separator towards high-temperature, large-rate, long-cycle lithium-ion batteries, Chin. Chem. Lett., 34(2023), No. 5, art. No. 107546. |
| [73] |
Y.D. Kuang, C.J. Chen, D. Kirsch, and L.B. Hu, Thick electrode batteries: Principles, opportunities, and challenges, Adv. Energy Mater., 9(2019), No. 33, art. No. 1901457. |
| [74] |
H.G. Jung, M.W. Jang, J. Hassoun, Y.K. Sun, and B. Scrosati, A high-rate long-life Li4Ti5O12/Li[Ni0.45Co0.1Mn1.45]O4 lithiumion battery, Nat. Commun., 2(2011), art. No. 516. |
| [75] |
T.P. Plateau, G. Boyer, and J. Park, Hyper-thick electrodes for lithium-ion batteries enabled by micro-electric-field process, Adv. Sci., 12(2025), No. 7, art. No. 2413444. |
| [76] |
S. Carelli and W.G. Bessler, Coupling lithium plating with SEI formation in a pseudo-3D model: A comprehensive approach to describe aging in lithium-ion cells, J. Electrochem. Soc., 169(2022), No. 5, art. No. 050539. |
| [77] |
C. Hou, J.H. Han, P. Liu, et al., Operando observations of SEI film evolution by mass-sensitive scanning transmission electron microscopy, Adv. Energy Mater., 9(2019), No. 45, art. No. 1902675. |
| [78] |
L.A. Blanquer, F. Marchini, J.R. Seitz, et al., Optical sensors for operando stress monitoring in lithium-based batteries containing solid-state or liquid electrolytes, Nat. Commun., 13(2022), art. No. 1153. |
| [79] |
|
| [80] |
W.K. Xu, Y.W. Yang, F. Shi, L.Y. Li, F.Z. Wen, and Q. Chen, Ultrasonic phased array imaging of gas evolution in a lithiumion battery, Cell Rep. Phys. Sci., 4(2023), No. 9, art. No. 101579. |
| [81] |
S.X. Zhu, L. Yang, J.W. Wen, et al., In operando measuring circumferential internal strain of 18650 Li-ion batteries by thin film strain gauge sensors, J. Power Sources, 516(2021), art. No. 230669. |
| [82] |
|
| [83] |
|
| [84] |
L. Xu, Y. Xiao, Y. Yang, et al., Operando quantified lithium plating determination enabled by dynamic capacitance measurement in working Li-ion batteries, Angew. Chem. Int. Ed., 61(2022), No. 39, art. No. e202210365. |
| [85] |
I.B. Mansir and P.C. Okonkwo, Component degradation in lithium-ion batteries and their sustainability: A concise overview, Sustainability, 17(2025), No. 3, art. No. 1000. |
| [86] |
P. Wang, G.Y. Zhao, Y.C. Pan, et al., Dual-salt electrolyte strategy enables stable interface reaction and high-performance lithium-ion batteries at low temperature, Chin. Chem. Lett., 36(2025), No. 11, art. No. 111190. |
| [87] |
G.J. Xu, M.S. Wang, Y.Z. Song, et al., Visualized detection of lithium plating on graphite anodes cycled under low temperature and fast charging, Adv. Funct. Mater., 35(2025), No. 2, art. No. 2412614. |
| [88] |
Y.K. Wang, D.Y. Dang, D.W. Li, J.Z. Hu, X.W. Zhan, and Y.T. Cheng, Effects of polymeric binders on the cracking behavior of silicon composite electrodes during electrochemical cycling, J. Power Sources, 438(2019), art. No. 226938. |
| [89] |
|
| [90] |
Y.D. Xin, C.C. Liu, N. Li, et al., In-situ monitoring of multiple signals evolution behaviour for commercial lithium-ion batteries during internal short circuit, Appl. Energy, 350(2023), art. No. 121754. |
| [91] |
|
| [92] |
M. Li, W.G. Chen, Z.W. Shen, et al., Characterization of temperature and strain changes in lithium-ion batteries based on a hinged differential lever sensitization fiber Bragg grating strain-temperature simultaneous-measurement sensor, Sensors, 24(2024), No. 2, art. No. 412. |
| [93] |
|
| [94] |
X.M. Zhong, L. Yang, N. Li, et al., In-situ characterizations and mechanism analysis of mechanical inhomogeneity in a prismatic battery module, J. Power Sources, 548(2022), art. No. 232053. |
| [95] |
J. Hedman, R. Mogensen, R. Younesi, and F. Björefors, Fiber optical detection of lithium plating at graphite anodes, Adv. Mater. Interfaces, 10(2023), No. 3, art. No. 2201665. |
| [96] |
|
| [97] |
|
| [98] |
|
| [99] |
|
| [100] |
|
| [101] |
|
| [102] |
|
| [103] |
|
| [104] |
L.S. Zhang, L.S. Liu, X.L. Gao, Y. Pan, X.H. Liu, and X.N. Feng, Modeling of Lithium plating in lithium ion batteries based on Monte Carlo method, J. Power Sources, 541(2022), art. No. 231568. |
| [105] |
|
| [106] |
Q.P. Zhang, P.Z. Li, C.H. Liu, et al., Heat generation and temperature rise characteristics of single overcharged lithium-ion batteries, J. Electrochem. Soc., 169(2022), No. 6, art. No. 060502. |
| [107] |
X.K. Lin, K. Khosravinia, X.S. Hu, J. Li, and W. Lu, Lithium plating mechanism, detection, and mitigation in lithium-ion batteries, Prog. Energy Combust. Sci., 87(2021), art. No. 100953. |
| [108] |
J.F. Wang, B.W. Chen, Y.H. Li, et al., Multiparameter warning of lithium-ion battery overcharge-thermal runaway, J. Energy Storage, 78(2024), art. No. 110088. |
| [109] |
K.S.N. Vikrant, E. McShane, A.M. Colclasure, B.D. McCloskey, and S. Allu, Quantification of dead lithium on graphite anode under fast charging conditions, J. Electrochem. Soc., 169(2022), No. 4, art. No. 040520. |
| [110] |
X.L. Peng, J. Han, Q. Zhang, Y. Xiang, and X.R. Hu, Realtime mechanical and thermal monitoring of lithium batteries with PVDF-TrFE thin films integrated within the battery, Sens. Actuat. A: Phys., 338(2022), art. No. 113484. |
| [111] |
Y. Yi, B. Wang, and A. Bermak, A low-cost strain gauge displacement sensor fabricated via shadow mask printing, Sensors, 19(2019), No. 21, art. No. 4713. |
| [112] |
Y.D. Su, Y. Preger, H. Burroughs, C.H. Sun, and P.R. Ohodnicki, Fiber optic sensing technologies for battery management systems and energy storage applications, Sensors, 21(2021), No. 4, art. No. 1397. |
| [113] |
Y. Hatano, J. Shin, J. Tanigawa, et al., High-precision robust monitoring of charge/discharge current over a wide dynamic range for electric vehicle batteries using diamond quantum sensors, Sci. Rep., 12(2022), art. No. 13991. |
| [114] |
C. Gardner, E. Langhammer, W.J. Du, et al., In-situ Li-ion pouch cell diagnostics utilising plasmonic based optical fibre sensors, Sensors, 22(2022), No. 3, art. No. 738. |
| [115] |
|
| [116] |
|
| [117] |
|
| [118] |
Z.L. Xiao, C. Liu, T.T. Zhao, et al., Review: Online monitoring of internal temperature in lithium-ion batteries, J. Electrochem. Soc., 170(2023), No. 5, art. No. 057517. |
| [119] |
P.X. Jia, Q.X. Zhang, Z.Q. Ren, et al., Self-powered flexible battery pressure sensor based on gelatin, Chem. Eng. J., 479(2024), art. No. 147586. |
| [120] |
|
| [121] |
Y.D. Li, L. Wang, Y.Z. Song, W.W. Wang, C. Lin, and X.M. He, Functional optical fiber sensors detecting imperceptible physical/chemical changes for smart batteries, Nano Micro Lett., 16(2024), No. 1, art. No. 154. |
| [122] |
Y. Shen, S. Wang, H.M. Li, K.L. Wang, and K. Jiang, An overview on in situ/operando battery sensing methodology through thermal and stress measurements, J. Energy Storage, 64(2023), art. No. 107164. |
| [123] |
|
| [124] |
|
| [125] |
L. Matuck, J.L. Pinto, C. Marques, and M. Nascimento, Simultaneous strain and temperature discrimination in 18650 Li-ion batteries using polarization-maintaining fiber Bragg gratings, Batteries, 8(2022), No. 11, art. No. 233. |
| [126] |
|
| [127] |
|
| [128] |
X.L. Gao, Z.M. Bao, L.S. Zhang, N.P. Brandon, G.J. Offer, and H.Z. Wang, Seeing the unseen: Real-time tracking of battery cycling-to-failure via surface strain, Joule, 10(2026), No. 3, art. No. 102272. |
| [129] |
M. Qasem, J. Stubblefield, M. Qandil, Y. Yassin, M. Haddadin, and M. Krishnamurthy, Real-time AI-enabled digital twin for battery health estimation and fast charging using partial-discharge data, eTransportation, 27(2026), art. No. 100528. |
| [130] |
X. Liu, Y. Lyu, J. Gao, C.F. He, M.M. Geng, and M.S. Fan, STL-LLM: A seasonal-trend decomposition-enhanced large language model for battery capacity aging trajectory prediction, eTransportation, 28(2026), art. No. 100549. |
| [131] |
J. Rhyu, J. Schaeffer, M.L. Li, et al., Systematic feature design for cycle life prediction of lithium-ion batteries during formation, Joule, 9(2025), No. 5, art. No. 101884. |
University of Science and Technology Beijing
/
| 〈 |
|
〉 |