US20100288077A1 - Method of making an alloy - Google Patents
Method of making an alloy Download PDFInfo
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- US20100288077A1 US20100288077A1 US12/465,865 US46586509A US2010288077A1 US 20100288077 A1 US20100288077 A1 US 20100288077A1 US 46586509 A US46586509 A US 46586509A US 2010288077 A1 US2010288077 A1 US 2010288077A1
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
- H01M10/00—Secondary cells; Manufacture thereof
- H01M10/05—Accumulators with non-aqueous electrolyte
- H01M10/052—Li-accumulators
- H01M10/0525—Rocking-chair batteries, i.e. batteries with lithium insertion or intercalation in both electrodes; Lithium-ion batteries
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F3/00—Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sintering; Apparatus specially adapted therefor ; Presses and furnaces
- B22F3/006—Amorphous articles
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B82—NANOTECHNOLOGY
- B82Y—SPECIFIC USES OR APPLICATIONS OF NANOSTRUCTURES; MEASUREMENT OR ANALYSIS OF NANOSTRUCTURES; MANUFACTURE OR TREATMENT OF NANOSTRUCTURES
- B82Y30/00—Nanotechnology for materials or surface science, e.g. nanocomposites
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- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
- C22C1/00—Making non-ferrous alloys
- C22C1/02—Making non-ferrous alloys by melting
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
- H01M4/00—Electrodes
- H01M4/02—Electrodes composed of, or comprising, active material
- H01M4/13—Electrodes for accumulators with non-aqueous electrolyte, e.g. for lithium-accumulators; Processes of manufacture thereof
- H01M4/134—Electrodes based on metals, Si or alloys
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
- H01M4/00—Electrodes
- H01M4/02—Electrodes composed of, or comprising, active material
- H01M4/36—Selection of substances as active materials, active masses, active liquids
- H01M4/362—Composites
- H01M4/364—Composites as mixtures
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
- H01M4/00—Electrodes
- H01M4/02—Electrodes composed of, or comprising, active material
- H01M4/36—Selection of substances as active materials, active masses, active liquids
- H01M4/38—Selection of substances as active materials, active masses, active liquids of elements or alloys
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F2999/00—Aspects linked to processes or compositions used in powder metallurgy
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
- H01M4/00—Electrodes
- H01M4/02—Electrodes composed of, or comprising, active material
- H01M2004/021—Physical characteristics, e.g. porosity, surface area
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
- H01M4/00—Electrodes
- H01M4/02—Electrodes composed of, or comprising, active material
- H01M4/36—Selection of substances as active materials, active masses, active liquids
- H01M4/58—Selection of substances as active materials, active masses, active liquids of inorganic compounds other than oxides or hydroxides, e.g. sulfides, selenides, tellurides, halogenides or LiCoFy; of polyanionic structures, e.g. phosphates, silicates or borates
- H01M4/583—Carbonaceous material, e.g. graphite-intercalation compounds or CFx
- H01M4/587—Carbonaceous material, e.g. graphite-intercalation compounds or CFx for inserting or intercalating light metals
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02E—REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
- Y02E60/00—Enabling technologies; Technologies with a potential or indirect contribution to GHG emissions mitigation
- Y02E60/10—Energy storage using batteries
Definitions
- the present disclosure broadly relates to methods for making metallic alloys.
- Electrodes are used in negative electrodes for lithium ion batteries. Negative electrodes containing such metal alloys generally exhibit higher capacities relative to intercalation-type anodes such as graphite. Typically, silicon-containing alloys are made directly from the respective component elements; for example, by a milling process.
- Alloys containing Fe, Si, Sn, and/or C are useful, for example, as active materials for use as a negative electrode material for a lithium ion battery.
- Small grain sizes of individual phases in such alloys are typically important for good performance as an active electrode material (i.e., reversible lithiation/delithiation). This can typically be achieved by rapid quenching (e.g., melt spinning or sputtering), or milling (e.g., mechanical alloying).
- the present disclosure provides a method of making an alloy, the method comprising alloying components comprising:
- Alloys prepared according to the present disclosure may be suitable for use as a negative electrode material in a lithium ion battery.
- the metallic element or metallic compound comprises at least one of carbon, tin, titanium, zinc, iron, or silicon.
- the alloy is amorphous.
- alloying comprises milling using milling media.
- the alloy comprises tin, iron, and silicon.
- the alloy comprises tin, iron, and carbon.
- the metallic compound comprises a second ferrosilicon having a second ratio of iron to silicon, and wherein the first ratio and the second ratio are different.
- alloys prepared according to the present disclosure can typically be prepared easier, faster, and less expensively than with conventional processes that use pure forms of the components used to make the alloy.
- this is because some grades of ferrosilicon (e.g., iron containing 50, 75, and 90 percent by weight of silicon) are commercially available by the ton at relatively low prices. Many different grades of ferrosilicon are readily available commercially.
- alloy refers to a substance having one or more metallic phases, and comprising two or more metallic elements
- alloy refers to a process that forms an alloy
- delivery refers to a process for removing lithium from an electrode material
- metal means of, relating to, or having the characteristics of a metal
- metal compound refers to compounds that include at least one metallic element
- metal element refers to all elemental metals (including tin), silicon, and carbon;
- mill refers to a device for alloying, grinding, pulverizing, or otherwise breaking down a material into small particles (examples include pebble mills, jet mills, ball mills, rod mills and attritor mills);
- milling refers to a process of placing a material in a mill and operating the mill to perform alloying, or to grind, pulverize, or break down the material into small or smaller particles;
- negative electrode refers to an electrode of a lithium ion battery (often called an anode) where electrochemical oxidation and delithiation occurs during a discharging process.
- Ferrosilicon is a metallic alloy of iron and silicon commonly prepared by fusing iron and silica in the presence of carbon in an electric furnace. It is of considerable importance in the manufacture of steel and cast iron. Accordingly, ferrosilicon is available commercially in various weight ratios of iron to silicon covering essentially the entire compositional range. Examples include 0.1:99, 1:99, 5:95, 10:90, 20:80, 30:70, 40:60, 50:50, 60:40, 70:30, 80:20, 90:10, 95:5, 99.9:0.1, although other ratios may also be used.
- Ferrosilicon with the compositions 50:50 (Fe:Si by weight) and 25:75 (Fe:Si by weight) are widely available in tonnage quantities, and at commodity prices that may be less that the constituent purified metallic elements (i.e., iron and silicon).
- At least one ferrosilicon is alloyed with at least one metallic element and/or metallic alloy.
- the metallic alloy may be any metallic alloy; for example, a ferrosilicon, an alloy of silicon and tin, or an alloy of carbon and iron.
- any compositional ratio of iron to silicon falls between the compositional ratios of the two ferrosilicon alloys.
- 50:50 Fe:Si and 25:75 Fe:Si ferrosilicon alloys it is possible to achieve all compositional ranges between 50 and 75 percent silicon by blending appropriate amounts of each. For values lying outside the corresponding range, pure elemental iron or silicon may be added in an amount that achieves a desired stoichiometry.
- Additional metallic elements and metallic alloys may optionally be incorporated in processes according to the present disclosure, may be readily obtained from commercial sources. Examples include carbon, silicon, tin, and transition metals (e.g., Fe, Ti, Y, V, Cu, Zr, Zn, Co, Mn, Mo, and Ni), and alloys thereof, although other metallic elements and metallic alloys may also be used.
- transition metals e.g., Fe, Ti, Y, V, Cu, Zr, Zn, Co, Mn, Mo, and Ni
- alloys thereof although other metallic elements and metallic alloys may also be used.
- Alloying may be conducted thermally; for example, in an electric arc furnace. Alloying may also be accomplished by mechanical methods such as, for example, milling.
- the alloying process may use ingot, chunk, powder, or other forms of ferrosilicon and optional metallic components to be included in that alloy.
- Milling techniques are generally useful for mechanically alloying metallic elements and/or metallic alloys; especially as powders.
- suitable milling techniques include jet milling, ball milling (e.g., using a planetary mill, vibrational mill, attritor mill, or a cylindrical or conical vessel). Jet mills abrade particles by impinging them against hard target substrates.
- Ball mills contain milling media that serve to grind material placed in the mill. Examples of suitable milling media include steel, porcelain, and/or ceramic media, which may be in the form of rods, balls, or other shapes. In general, the process conditions will vary with the type of milling technique used, and will be apparent to those of ordinary skill in the milling art.
- milling should be conducted in a controlled oxygen environment; for example, in an inert gas (e.g., nitrogen, helium, and/or argon) environment.
- an inert gas e.g., nitrogen, helium, and/or argon
- the use of preformed metallic alloys significantly reduces the processing time required for forming desired alloys as compared to using pure metallic elements.
- methods according to the present disclosure are especially useful for mechanically alloying metallic element powders and/or metallic alloy powders.
- Electrode compositions e.g., negative electrode compositions
- Electrode compositions for use in lithium ion batteries.
- the resultant alloy may be formed such that it is substantially free of crystallites greater than 50 nanometers in size (i.e., the maximum dimension of each crystallite).
- the resultant alloy may contain less than 5 percent by volume, less than one percent by volume, or even less than 0.1 percent by volume of crystallites greater than 50 nanometers in size.
- the resultant alloy may be formed as an amorphous composition.
- Exemplary alloys include silicon alloys wherein the active material comprises from about 50 to about 85 mole percent silicon, from about 5 to about 25 mole percent iron, from about 0 to about 12 mole percent titanium, and from about 0 to about 12 mole percent carbon.
- Exemplary alloys of silicon, iron and additional elements may be found in, for example,
- a milling aid may optionally be added to the metallic components being alloyed.
- milling aids include one or more saturated higher fatty acids (e.g., stearic acid, lauric acid, and palmitic acid) and salts thereof, hydrocarbons such as mineral oil, dodecane, polyethylene powder.
- the amount of any optional milling aid is less than 5 percent, typically less than 1 percent of the millbase.
- Graphite1 A graphite powder available as TIMREX SFG44 from TIMCAL Ltd., Bodio, Switzerland.
- Graphite2 A graphite powder with an average particle size of 24.4 micrometers and a 3.2 m 2 /g BET surface area available as MAGE from Hitachi Chemical Co. Ltd., Tokyo, Japan LiOH-20 A 20 percent solution of lithium hydroxide in water, prepared from LiOH—H 2 O and deionized water. LiOH—H 2 O Lithium hydroxide monohydrate, 98+%, A.C.S. Reagent available from Sigma-Aldrich Co, St. Louis, MO.
- PAA-34 A polyacrylic acid solution having a weight average molecular weight of 250,000 g/mole available as a 34 percent solution in water from Sigma-Aldrich Co.
- PAA-Li A 10 percent polyacrylic acid - lithium salt solution in water prepared by titrating PAA-34 with LiOH-20 until fully neutralized and adding deionized water to obtain the desired 10 percent concentration.
- Ti1 325 mesh titanium powder 99.5 percent pure, available from Alfa Aesar.
- X-ray diffraction patterns were collected using a Siemens Model KRISTALLOFLEX 805 D500 diffractometer equipped with a copper target x-ray tube and a diffracted beam monochromator.
- the X-ray diffraction patterns were collected using scattering angles between 20 and 60 degrees [two-theta] stepped at 0.05 degrees [two-theta].
- the crystalline domain size was calculated from the width of x-ray diffraction peaks using the Scherrer equation.
- SiFe alloy Large grain SiFe alloy was prepared by arc melting 120.277 grams (g) of Si1 and 79.723 g of Fe1.
- the Si/Fe large grain alloy powder 120 g was placed in the 5 liter, steel chamber of a ball mill (Model 611, Jar size 1 available from U.S. Stoneware, Ohio).
- the chamber was cylindrical in shape with an internal diameter of about 18.8 cm (7.4 inch) and a length of about 17.1 cm (6.75 inch).
- An X-ray diffraction pattern of the Si 75 Fe 25 alloy ingot showed crystalline Si and crystalline FeSi 2 .
- An X-ray diffraction pattern of Powder A showed nanostructures with small grain size for the FeSi 2 phase and a virtually amorphous Si phase.
- the term “amorphous” is used in the Examples to describe materials that have no defined X-ray diffraction peak indicative of a crystalline phase.
- FerroSi75 (59.27 g) and FerroSi50 (72.15 g) were milled used the procedure described in Comparative Example A, except the milling time was 7 days. After milling, a Si/Fe alloy powder containing about 75 mole percent silicon and 25 mole percent iron was produced, Powder 1.
- the X-ray diffraction pattern of the starting FerroSi75 showed peaks characteristic of crystalline Si and FeSi 2 phases.
- the X-ray diffraction pattern of the starting FerroSi50 showed peaks characteristic of crystalline FeSi 2 phases with small trace of crystalline Si.
- the x-ray diffraction pattern of Powder 1 showed peaks characteristic of nanocrystalline FeSi 2 having a grain size less than 50 nm.
- the X-ray diffraction pattern of Powder 1 did not contain peaks from Si, indicating that the Si phase in the ball milled alloy was amorphous.
- FerroSi75 (83.74 g), 45.55 g of FerroSi50, and 2.38 g of Graphite1 were milled using the procedure described in Comparative Example A, except the milling time was 9 days.
- the X-ray diffraction pattern of Powder 2 showed peaks characteristic of nanocrystalline FeSi 2 with a grain size less than 50 nm.
- the X-ray diffraction pattern of Powder 2 did not contain peaks from Si, indicating that the Si phase in the alloy was amorphous. From stoichiometry, this alloy also contained a SiC phase, however, the X-ray diffraction pattern of the ball milled alloy did not contain peaks from SiC, indicating that this phase was amorphous.
- FerroSi75 (111.70 g), 15.08 g of FerroSi50, and 5.10 g of Graphite1 were milled using the procedure described in Example 2. After milling, a Si/Fe/C alloy powder containing about 75 mole percent silicon, 15 mole percent iron and 10 mole percent carbon was produced, Powder 3.
- the x-ray diffraction pattern of Powder 3 showed peaks characteristic of nanocrystalline FeSi 2 with a grain size less than 50 nm.
- the x-ray diffraction pattern of Powder 3 did not contain peaks from Si, indicating that the Si phase in the alloy was amorphous. From stoichiometry, this alloy also contained a SiC phase, however, the X-ray diffraction pattern of the alloy did not contain peaks from SiC, indicating that this phase was amorphous.
- FerroSi75 (46.21 g), 69.06 g of FerroSi50, and 15.97 g of Sn1 were milled using the procedure described in Comparative Example A. After milling, a Si/Fe/Sn alloy powder containing about 71 mole percent silicon, 25 mole percent iron and 4 mole percent tin was produced, Powder 4.
- the X-ray diffraction pattern of Powder 4 showed peaks characteristic of nanocrystalline FeSi 2 with a grain size less than 50 nm.
- the x-ray diffraction pattern of Powder 4 did not contain peaks from Si and Sn, indicating that the Si and Sn phases in the ball milled alloy were amorphous.
- FerroSi75 (46.02 g), 62.82 g of FerroSi50, 16.89 g of Sn1, and 4.27 g of Graphite 1 were placed in the chamber of the ball mill described in Comparative Example A. Milling used the procedure described in Comparative Example A. After milling, a Si/Fe/Sn/C alloy powder containing about 64 mole percent silicon, 22 mole percent iron, 4 mole percent tin and 10 mole percent carbon was produced, Powder 5. The X-ray diffraction pattern of Powder 5 showed peaks characteristic of nanocrystalline FeSi 2 with a grain size less than 50 nm. The X-ray diffraction pattern of Powder 5 did not contain peaks from Si, Sn and SiC, indicating that the Si, Sn and SiC phases in the alloy were amorphous.
- FerroSi75 64.29 g
- 42.77 g of FerroSi50, 16.14 g of Sn1, and 8.14 g of Ti1 were milled using the procedure described in Comparative Example A, except the milling time was 13 days.
- a Si/Fe/Sn/Ti alloy powder containing about 71 mole percent silicon, 20 mole percent iron, 4 mole percent tin and 5 mole percent titanium was produced, Powder 6.
- the X-ray diffraction pattern of Powder 6 showed peaks characteristic of nanocrystalline FeSi 2 with a grain size less than 50 nm.
- the X-ray diffraction pattern of Powder 6 did not contain peaks from Si, Sn and TiSi 2 (and/or FeTiSi 2 ), indicating that the Si, Sn and TiSi 2 (and/or FeTiSi 2 ) phase alloy were amorphous.
- FerroSi75 (1.27 g), 0.69 g of FerroSi50, and 0.04 g of Graphite1 were placed in a 45-milliliter tungsten carbide chamber, Model 8001 from Spex Certiprep Ltd., Metuchen, N.J.
- 28 tungsten carbide balls (about 108 g) having a 0.79 cm (0.3125 inch) diameter were added to the chamber.
- the chamber was placed in a dual mixer/mill, Model 8000-D from Spex Certiprep Ltd.
- the chamber was vibrated by the dual mixer/mill for two hours.
- the vessel was cooled with an air jet during the two hour milling period, maintaining a chamber temperature of about 30° C.
- Powder 7 After milling, a Si/Fe/C alloy powder containing about 75 mole percent silicon, 20 mole percent iron, and 5 mole percent carbon was produced, Powder 7.
- the x-ray diffraction pattern of Powder 7 showed peaks characteristic of nanocrystalline Si and FeSi 2 with a grain size 6 nm and 12 nm, respectively. From stoichiometry, this alloy also contained SiC phases, however, the X-ray diffraction pattern of Powder 7 did not contain peaks from SiC, indicating that this phase was amorphous.
- Alloy powder (1.84 g) and 1.6 g of PAA-Li were mixed in a 45-milliliter stainless steel vessel using four, 1.27 cm (0.5 inch) tungsten carbide balls. The mixing was done in a Planetary Micro Mill Pulverisette 7 from Fritsch, Germany at speed 2 for one hour. The resulting solution was hand spread onto a 10-micrometer thick Cu foil using a gap die (typically 3 mil gap). The sample was then dried in a vacuum oven at 120° C. for 1-2 hours producing an alloy electrode film. Circles, 16 mm in diameter, were then punched out of the alloy electrode film and were used as an alloy electrode for a cell (below).
- Half coin cells were prepared using 2325 button cells. All of the components were dried prior to assembly and the cell preparations were done in a dry room with a ⁇ 70° C. dew point. The cells were constructed from the following components and in the following order, from the bottom up. Cu Spacer/Li metal film/Separator/alloy electrode/Cu spacer.
- Each cell consisted of a 20 mm diameter ⁇ 0.762 mm (30 mil) thick disk of Cu spacer, a 16 mm diameter disk of alloy electrode, a 20 mm diameter micro porous separators (CELGAR2400p available from Separation Products, Hoechst Celanese Corp., Charlotte, N.C.), 18 mm diameter ⁇ 0.38 mm thick disk of Li metal film (lithium ribbon available from Aldrich Chemical Co., Milwaukee, Wis.) and a 20 mm diameter ⁇ 0.762 mm (30 mil) disk of copper spacer.
- the electrolyte was a solution containing 90 percent by weight of an EC/DEC solution (2/1 by volume) and 10 percent by weight FEC with LiPF 6 used as the conducting salt at a 1 M concentration. Prior to adding the LiPF 6 , the mixture was dried over molecular sieve (3A type) for 12 hours. The cell was filled with 100 microliters of electrolyte solution. The cell was crimp sealed prior to testing.
- Cells were cycled from 0.005V to 0.90V at specific rate of 100 mA/g-alloy with trickle down to 10 mA/g at the end of discharge (delithiation) for the first cycle. From then on, cells were cycled in the same voltage range but at 200 mA/g-alloy and trickle down to 20 mA/g-alloy at the end of discharge. Cells were allowed 15 min rest at open circuit at the end of every half cycle.
- An alloy electrode film was prepared using Powder 4.
- Powder 4 was first sized by milling in heptane.
- Powder 4 (4 g) and 20 g of heptane were placed in a 45-milliliter stainless steel vessel containing 17.62 g of 9.5 mm (0.375 inch) diameter chromium steel balls and 22.98 g of 6.35 mm (0.25 inch) diameter chromium steel balls.
- the milling was done in a Planetary Micro Mill Pulverisette 7 at a speed 5 for one hour. Excess heptane was removed, and the wet sample was dried at 80° C. for 1 hour.
- An alloy electrode film was prepared from the sized powder in the following manner.
- Sized Powder 4 (0.96 g), 0.96 g of Graphite2, 0.8 g of PAA-Li, and 4.5 g of deionized water, were mixed in a 45-milliliter stainless steel vessel using four 12.7 mm (0.5 inch) diameter tungsten carbide balls. The mixing was done in the Planetary Micro Mill Pulverisette 7 at speed 2 for one hour. The resulting solution was hand spread onto a 10-micrometer thick Cu foil using an 8-mil gap die. The sample was air dried, then calendered and dried in a vacuum oven at 120° C. for 1 hour. Circles, 16 mm in diameter, were then punched out of the alloy electrode film and were used as an alloy electrode for a cell.
- alloy powders prepared according to the present disclosure when fabricated into an electrode and further fabricated into a cell, showed stable capacity for many cycles, making them suitable for use as active anode materials in battery applications, including rechargeable lithium ion battery applications.
Abstract
A method of making an alloy comprises alloying components comprising: ferrosilicon having a ratio of iron to silicon; and at least one of a metallic element or a metallic compound. The alloy may be used in electrode compositions for lithium ion batteries.
Description
- The present disclosure broadly relates to methods for making metallic alloys.
- Metallic alloys are used in negative electrodes for lithium ion batteries. Negative electrodes containing such metal alloys generally exhibit higher capacities relative to intercalation-type anodes such as graphite. Typically, silicon-containing alloys are made directly from the respective component elements; for example, by a milling process.
- Alloys containing Fe, Si, Sn, and/or C are useful, for example, as active materials for use as a negative electrode material for a lithium ion battery. Small grain sizes of individual phases in such alloys are typically important for good performance as an active electrode material (i.e., reversible lithiation/delithiation). This can typically be achieved by rapid quenching (e.g., melt spinning or sputtering), or milling (e.g., mechanical alloying).
- Current common practice in the industry uses powdered purified elemental metals as raw materials to fabricate active electrode materials using processes that are typically laborious, time-consuming, and/or costly.
- In one aspect, the present disclosure provides a method of making an alloy, the method comprising alloying components comprising:
- a first ferrosilicon having a first ratio of iron to silicon; and
- at least one of a metallic element or a metallic compound, wherein the alloy is substantially free of crystallites greater than 50 nanometers in size. Alloys prepared according to the present disclosure may be suitable for use as a negative electrode material in a lithium ion battery.
- In some embodiments, the metallic element or metallic compound comprises at least one of carbon, tin, titanium, zinc, iron, or silicon. In some embodiments, the alloy is amorphous. In some embodiments, alloying comprises milling using milling media. In some embodiments, the alloy comprises tin, iron, and silicon. In some embodiments, the alloy comprises tin, iron, and carbon.
- In some embodiments, the metallic compound comprises a second ferrosilicon having a second ratio of iron to silicon, and wherein the first ratio and the second ratio are different.
- Advantageously, alloys prepared according to the present disclosure can typically be prepared easier, faster, and less expensively than with conventional processes that use pure forms of the components used to make the alloy. In part, this is because some grades of ferrosilicon (e.g., iron containing 50, 75, and 90 percent by weight of silicon) are commercially available by the ton at relatively low prices. Many different grades of ferrosilicon are readily available commercially.
- As used herein:
- the term “alloy” refers to a substance having one or more metallic phases, and comprising two or more metallic elements;
- the term “alloying” refers to a process that forms an alloy;
- the term “delithiation” refer to a process for removing lithium from an electrode material;
- the term “metallic” means of, relating to, or having the characteristics of a metal;
- the term “metallic compound” refers to compounds that include at least one metallic element;
- the term “metallic element” refers to all elemental metals (including tin), silicon, and carbon;
- the term “mill” refers to a device for alloying, grinding, pulverizing, or otherwise breaking down a material into small particles (examples include pebble mills, jet mills, ball mills, rod mills and attritor mills);
- the term “milling” refers to a process of placing a material in a mill and operating the mill to perform alloying, or to grind, pulverize, or break down the material into small or smaller particles; and
- the term “negative electrode” refers to an electrode of a lithium ion battery (often called an anode) where electrochemical oxidation and delithiation occurs during a discharging process.
- Ferrosilicon is a metallic alloy of iron and silicon commonly prepared by fusing iron and silica in the presence of carbon in an electric furnace. It is of considerable importance in the manufacture of steel and cast iron. Accordingly, ferrosilicon is available commercially in various weight ratios of iron to silicon covering essentially the entire compositional range. Examples include 0.1:99, 1:99, 5:95, 10:90, 20:80, 30:70, 40:60, 50:50, 60:40, 70:30, 80:20, 90:10, 95:5, 99.9:0.1, although other ratios may also be used. Ferrosilicon with the compositions 50:50 (Fe:Si by weight) and 25:75 (Fe:Si by weight) are widely available in tonnage quantities, and at commodity prices that may be less that the constituent purified metallic elements (i.e., iron and silicon).
- According to the present disclosure, at least one ferrosilicon is alloyed with at least one metallic element and/or metallic alloy. The metallic alloy may be any metallic alloy; for example, a ferrosilicon, an alloy of silicon and tin, or an alloy of carbon and iron. In those embodiments of the present disclosure using two compositionally different ferrosilicon alloys, it is possible to achieve any compositional ratio of iron to silicon that falls between the compositional ratios of the two ferrosilicon alloys. For example, using 50:50 Fe:Si and 25:75 Fe:Si ferrosilicon alloys, it is possible to achieve all compositional ranges between 50 and 75 percent silicon by blending appropriate amounts of each. For values lying outside the corresponding range, pure elemental iron or silicon may be added in an amount that achieves a desired stoichiometry.
- Additional metallic elements and metallic alloys may optionally be incorporated in processes according to the present disclosure, may be readily obtained from commercial sources. Examples include carbon, silicon, tin, and transition metals (e.g., Fe, Ti, Y, V, Cu, Zr, Zn, Co, Mn, Mo, and Ni), and alloys thereof, although other metallic elements and metallic alloys may also be used.
- Alloying may be conducted thermally; for example, in an electric arc furnace. Alloying may also be accomplished by mechanical methods such as, for example, milling. The alloying process may use ingot, chunk, powder, or other forms of ferrosilicon and optional metallic components to be included in that alloy.
- Milling techniques are generally useful for mechanically alloying metallic elements and/or metallic alloys; especially as powders. Examples of suitable milling techniques include jet milling, ball milling (e.g., using a planetary mill, vibrational mill, attritor mill, or a cylindrical or conical vessel). Jet mills abrade particles by impinging them against hard target substrates. Ball mills contain milling media that serve to grind material placed in the mill. Examples of suitable milling media include steel, porcelain, and/or ceramic media, which may be in the form of rods, balls, or other shapes. In general, the process conditions will vary with the type of milling technique used, and will be apparent to those of ordinary skill in the milling art.
- In general, milling should be conducted in a controlled oxygen environment; for example, in an inert gas (e.g., nitrogen, helium, and/or argon) environment. In general, the use of preformed metallic alloys significantly reduces the processing time required for forming desired alloys as compared to using pure metallic elements. For example, methods according to the present disclosure are especially useful for mechanically alloying metallic element powders and/or metallic alloy powders.
- Mechanically alloyed compositions prepared according to the present disclosure are useful, for example, for forming electrode compositions (e.g., negative electrode compositions) for use in lithium ion batteries.
- It may be desirable to use milling conditions that result in few if any crystallites of significant size being present in the resultant alloy. For example, the resultant alloy may be formed such that it is substantially free of crystallites greater than 50 nanometers in size (i.e., the maximum dimension of each crystallite). The resultant alloy may contain less than 5 percent by volume, less than one percent by volume, or even less than 0.1 percent by volume of crystallites greater than 50 nanometers in size. In some embodiments, the resultant alloy may be formed as an amorphous composition.
- One desirable method of mechanically alloying metallic elements and/or metallic alloys is described in U.S. application Ser. No. ______, entitled “LOW ENERGY MILLING METHOD, ALLOY, AND NEGATIVE ELECTRODE COMPOSITION” (Attorney Docket No. 65465US002), filed contemporaneously herewith.
- Exemplary alloys include silicon alloys wherein the active material comprises from about 50 to about 85 mole percent silicon, from about 5 to about 25 mole percent iron, from about 0 to about 12 mole percent titanium, and from about 0 to about 12 mole percent carbon. Exemplary alloys of silicon, iron and additional elements may be found in, for example,
- U.S. Pat. Appl. Publ. Nos. 2005/0031957 A1 (Christensen et al), 2007/0020521 A1 (Obrovac et al.), and 2007/0020522 A1 (Obrovac et al.).
- If mechanical alloying is used, a milling aid may optionally be added to the metallic components being alloyed. Examples of milling aids include one or more saturated higher fatty acids (e.g., stearic acid, lauric acid, and palmitic acid) and salts thereof, hydrocarbons such as mineral oil, dodecane, polyethylene powder. In general the amount of any optional milling aid is less than 5 percent, typically less than 1 percent of the millbase.
- Objects and advantages of this disclosure are further illustrated by the following examples, but the particular materials and amounts thereof recited in these examples, as well as other conditions and details, should not be construed to unduly limit this disclosure.
- Unless otherwise noted, all parts, percentages, ratios, etc. in the Examples and the rest of the specification are by weight.
- The following Abbreviations are used in the Examples.
-
ABBRE- VIATION DESCRIPTION DEC Diethyl carbonate from Ferro Corp. EC Ethylene carbonate from Ferro Corp., Zachary, LA Fe1 Iron pieces having irregular shape with a size 12 mm or less, 99.97 percent pure, available from Alfa Aesar. FEC Fluoroethylene carbonate from Fujian Chuangxin Science and Develops Co., LTD, Fujian, China FerroSi50 Ferrosilicon containing 47.92 percent of silicon and 51.35 percent of iron available from Globe Metallurgical, Inc. Crushed and sized to less than 500 micrometers. FerroSi75 Ferrosilicon containing 73.53 percent of silicon and 24.88 percent by weight of iron available from Globe Metallurgical, Inc., Beverly, OH. Crushed and sized to less than 500 micrometers. Graphite1 A graphite powder available as TIMREX SFG44 from TIMCAL Ltd., Bodio, Switzerland. Graphite2 A graphite powder with an average particle size of 24.4 micrometers and a 3.2 m2/g BET surface area available as MAGE from Hitachi Chemical Co. Ltd., Tokyo, Japan LiOH-20 A 20 percent solution of lithium hydroxide in water, prepared from LiOH—H2O and deionized water. LiOH—H2O Lithium hydroxide monohydrate, 98+%, A.C.S. Reagent available from Sigma-Aldrich Co, St. Louis, MO. PAA-34 A polyacrylic acid solution having a weight average molecular weight of 250,000 g/mole available as a 34 percent solution in water from Sigma-Aldrich Co. PAA-Li A 10 percent polyacrylic acid - lithium salt solution in water prepared by titrating PAA-34 with LiOH-20 until fully neutralized and adding deionized water to obtain the desired 10 percent concentration. Si1 Silicon pieces with a size of 10 cm or less, 98.4 percent pure, available from Alfa Aesar, Ward Hill, MA. Sn1 325 mesh tin powder, 99.8 percent pure, available from Alfa Aesar. Ti1 325 mesh titanium powder, 99.5 percent pure, available from Alfa Aesar. - X-ray diffraction patterns were collected using a Siemens Model KRISTALLOFLEX 805 D500 diffractometer equipped with a copper target x-ray tube and a diffracted beam monochromator. The X-ray diffraction patterns were collected using scattering angles between 20 and 60 degrees [two-theta] stepped at 0.05 degrees [two-theta]. The crystalline domain size was calculated from the width of x-ray diffraction peaks using the Scherrer equation.
- Large grain SiFe alloy was prepared by arc melting 120.277 grams (g) of Si1 and 79.723 g of Fe1. The Si75Fe25 ingot, containing about 75 mole percent silicon and 25 mole percent iron, was crushed and sized to less than 150 micrometers. The Si/Fe large grain alloy powder (120 g), was placed in the 5 liter, steel chamber of a ball mill (Model 611, Jar size 1 available from U.S. Stoneware, Ohio). The chamber was cylindrical in shape with an internal diameter of about 18.8 cm (7.4 inch) and a length of about 17.1 cm (6.75 inch). In addition to the large grain alloy powder, 10 kg of 1.27 cm (0.5 inch) diameter chromium steel balls, one cylindrical steel bar 23.2 cm (9.125 inch) length×1.27 cm (0.5 inch) diameter and two cylindrical steel bars 21.5 cm (8.625 inch) length×1.27 cm (0.5 inch) diameter were added to the chamber. The chamber was purged with N2 and milled at 85 rpm (revolutions per minute) for 6 days. After milling, a Si/Fe powder alloy containing about 75 mole percent silicon and 25 mole percent iron was produced (Powder A).
- An X-ray diffraction pattern of the Si75Fe25 alloy ingot showed crystalline Si and crystalline FeSi2. An X-ray diffraction pattern of Powder A showed nanostructures with small grain size for the FeSi2 phase and a virtually amorphous Si phase. The term “amorphous” is used in the Examples to describe materials that have no defined X-ray diffraction peak indicative of a crystalline phase.
- FerroSi75 (59.27 g) and FerroSi50 (72.15 g) were milled used the procedure described in Comparative Example A, except the milling time was 7 days. After milling, a Si/Fe alloy powder containing about 75 mole percent silicon and 25 mole percent iron was produced, Powder 1. The X-ray diffraction pattern of the starting FerroSi75 showed peaks characteristic of crystalline Si and FeSi2 phases. The X-ray diffraction pattern of the starting FerroSi50 showed peaks characteristic of crystalline FeSi2 phases with small trace of crystalline Si. The x-ray diffraction pattern of Powder 1 showed peaks characteristic of nanocrystalline FeSi2 having a grain size less than 50 nm. The X-ray diffraction pattern of Powder 1 did not contain peaks from Si, indicating that the Si phase in the ball milled alloy was amorphous.
- FerroSi75 (83.74 g), 45.55 g of FerroSi50, and 2.38 g of Graphite1 were milled using the procedure described in Comparative Example A, except the milling time was 9 days. After milling, a Si/Fe/C alloy powder containing about 75 mole percent silicon, 20 mole percent iron and 5 mole percent carbon was produced, Powder 2. The X-ray diffraction pattern of Powder 2, showed peaks characteristic of nanocrystalline FeSi2 with a grain size less than 50 nm. The X-ray diffraction pattern of Powder 2 did not contain peaks from Si, indicating that the Si phase in the alloy was amorphous. From stoichiometry, this alloy also contained a SiC phase, however, the X-ray diffraction pattern of the ball milled alloy did not contain peaks from SiC, indicating that this phase was amorphous.
- FerroSi75 (111.70 g), 15.08 g of FerroSi50, and 5.10 g of Graphite1 were milled using the procedure described in Example 2. After milling, a Si/Fe/C alloy powder containing about 75 mole percent silicon, 15 mole percent iron and 10 mole percent carbon was produced, Powder 3. The x-ray diffraction pattern of Powder 3 showed peaks characteristic of nanocrystalline FeSi2 with a grain size less than 50 nm. The x-ray diffraction pattern of Powder 3 did not contain peaks from Si, indicating that the Si phase in the alloy was amorphous. From stoichiometry, this alloy also contained a SiC phase, however, the X-ray diffraction pattern of the alloy did not contain peaks from SiC, indicating that this phase was amorphous.
- FerroSi75 (46.21 g), 69.06 g of FerroSi50, and 15.97 g of Sn1 were milled using the procedure described in Comparative Example A. After milling, a Si/Fe/Sn alloy powder containing about 71 mole percent silicon, 25 mole percent iron and 4 mole percent tin was produced, Powder 4. The X-ray diffraction pattern of Powder 4 showed peaks characteristic of nanocrystalline FeSi2 with a grain size less than 50 nm. The x-ray diffraction pattern of Powder 4 did not contain peaks from Si and Sn, indicating that the Si and Sn phases in the ball milled alloy were amorphous.
- FerroSi75 (46.02 g), 62.82 g of FerroSi50, 16.89 g of Sn1, and 4.27 g of Graphite 1 were placed in the chamber of the ball mill described in Comparative Example A. Milling used the procedure described in Comparative Example A. After milling, a Si/Fe/Sn/C alloy powder containing about 64 mole percent silicon, 22 mole percent iron, 4 mole percent tin and 10 mole percent carbon was produced, Powder 5. The X-ray diffraction pattern of Powder 5 showed peaks characteristic of nanocrystalline FeSi2 with a grain size less than 50 nm. The X-ray diffraction pattern of Powder 5 did not contain peaks from Si, Sn and SiC, indicating that the Si, Sn and SiC phases in the alloy were amorphous.
- FerroSi75 (64.29 g), 42.77 g of FerroSi50, 16.14 g of Sn1, and 8.14 g of Ti1 were milled using the procedure described in Comparative Example A, except the milling time was 13 days. After milling, a Si/Fe/Sn/Ti alloy powder containing about 71 mole percent silicon, 20 mole percent iron, 4 mole percent tin and 5 mole percent titanium was produced, Powder 6. The X-ray diffraction pattern of Powder 6, showed peaks characteristic of nanocrystalline FeSi2 with a grain size less than 50 nm. The X-ray diffraction pattern of Powder 6 did not contain peaks from Si, Sn and TiSi2 (and/or FeTiSi2), indicating that the Si, Sn and TiSi2 (and/or FeTiSi2) phase alloy were amorphous.
- FerroSi75 (1.27 g), 0.69 g of FerroSi50, and 0.04 g of Graphite1 were placed in a 45-milliliter tungsten carbide chamber, Model 8001 from Spex Certiprep Ltd., Metuchen, N.J. In addition to the powder, 28 tungsten carbide balls (about 108 g) having a 0.79 cm (0.3125 inch) diameter were added to the chamber. The chamber was placed in a dual mixer/mill, Model 8000-D from Spex Certiprep Ltd. The chamber was vibrated by the dual mixer/mill for two hours. The vessel was cooled with an air jet during the two hour milling period, maintaining a chamber temperature of about 30° C. After milling, a Si/Fe/C alloy powder containing about 75 mole percent silicon, 20 mole percent iron, and 5 mole percent carbon was produced, Powder 7. The x-ray diffraction pattern of Powder 7 showed peaks characteristic of nanocrystalline Si and FeSi2 with a grain size 6 nm and 12 nm, respectively. From stoichiometry, this alloy also contained SiC phases, however, the X-ray diffraction pattern of Powder 7 did not contain peaks from SiC, indicating that this phase was amorphous.
- FerroSi75, 1.70 g, and FerroSi50, 0.23 g and 0.08 g Graphite 1 were milled using the procedure described in Example 7. After milling, a Si/Fe/C alloy powder containing about 75 mole percent silicon, 15 mole percent iron and 10 mole percent carbon was produced, Powder 8. The x-ray diffraction pattern of Powder 8 showed peaks characteristic of nanocrystalline Si and FeSi2 with a grain size of 11 nm and 12 nm, respectively. From stoichiometry, this alloy also contained a SiC phase, however, the X-ray diffraction pattern of Powder 8 did not contain peaks from SiC, indicating that this phase was amorphous.
- Alloy powder (1.84 g) and 1.6 g of PAA-Li were mixed in a 45-milliliter stainless steel vessel using four, 1.27 cm (0.5 inch) tungsten carbide balls. The mixing was done in a Planetary Micro Mill Pulverisette 7 from Fritsch, Germany at speed 2 for one hour. The resulting solution was hand spread onto a 10-micrometer thick Cu foil using a gap die (typically 3 mil gap). The sample was then dried in a vacuum oven at 120° C. for 1-2 hours producing an alloy electrode film. Circles, 16 mm in diameter, were then punched out of the alloy electrode film and were used as an alloy electrode for a cell (below).
- Half coin cells were prepared using 2325 button cells. All of the components were dried prior to assembly and the cell preparations were done in a dry room with a −70° C. dew point. The cells were constructed from the following components and in the following order, from the bottom up. Cu Spacer/Li metal film/Separator/alloy electrode/Cu spacer. Each cell consisted of a 20 mm diameter×0.762 mm (30 mil) thick disk of Cu spacer, a 16 mm diameter disk of alloy electrode, a 20 mm diameter micro porous separators (CELGAR2400p available from Separation Products, Hoechst Celanese Corp., Charlotte, N.C.), 18 mm diameter×0.38 mm thick disk of Li metal film (lithium ribbon available from Aldrich Chemical Co., Milwaukee, Wis.) and a 20 mm diameter×0.762 mm (30 mil) disk of copper spacer. The electrolyte was a solution containing 90 percent by weight of an EC/DEC solution (2/1 by volume) and 10 percent by weight FEC with LiPF6 used as the conducting salt at a 1 M concentration. Prior to adding the LiPF6, the mixture was dried over molecular sieve (3A type) for 12 hours. The cell was filled with 100 microliters of electrolyte solution. The cell was crimp sealed prior to testing.
- Cells were cycled from 0.005V to 0.90V at specific rate of 100 mA/g-alloy with trickle down to 10 mA/g at the end of discharge (delithiation) for the first cycle. From then on, cells were cycled in the same voltage range but at 200 mA/g-alloy and trickle down to 20 mA/g-alloy at the end of discharge. Cells were allowed 15 min rest at open circuit at the end of every half cycle.
- An alloy electrode film and three coin cells were prepared and tested according to the Procedure for Preparing an Alloy Electrode, Cell Assembly and Cell Testing using Powder 1. Results are reported Table 1.
- An alloy electrode film and three coin cells were prepared and tested according to the Procedure for Preparing an Alloy Electrode, Cell Assembly and Cell Testing using Powder 4. Results are reported Table 1.
- An alloy electrode film and three coin cells were prepared and tested according to the Procedure for Preparing an Alloy Electrode, Cell Assembly and Cell Testing using Powder 5. Results are reported Table 1.
- An alloy electrode film and three coin cells were prepared and tested according to the Procedure for Preparing an Alloy Electrode, Cell Assembly and Cell Testing using Powder 6. Results are reported Table 1.
- An alloy electrode film was prepared using Powder 4. Powder 4 was first sized by milling in heptane. Powder 4 (4 g) and 20 g of heptane were placed in a 45-milliliter stainless steel vessel containing 17.62 g of 9.5 mm (0.375 inch) diameter chromium steel balls and 22.98 g of 6.35 mm (0.25 inch) diameter chromium steel balls. The milling was done in a Planetary Micro Mill Pulverisette 7 at a speed 5 for one hour. Excess heptane was removed, and the wet sample was dried at 80° C. for 1 hour. An alloy electrode film was prepared from the sized powder in the following manner. Sized Powder 4 (0.96 g), 0.96 g of Graphite2, 0.8 g of PAA-Li, and 4.5 g of deionized water, were mixed in a 45-milliliter stainless steel vessel using four 12.7 mm (0.5 inch) diameter tungsten carbide balls. The mixing was done in the Planetary Micro Mill Pulverisette 7 at speed 2 for one hour. The resulting solution was hand spread onto a 10-micrometer thick Cu foil using an 8-mil gap die. The sample was air dried, then calendered and dried in a vacuum oven at 120° C. for 1 hour. Circles, 16 mm in diameter, were then punched out of the alloy electrode film and were used as an alloy electrode for a cell. Three coin cells were prepared according to the second paragraph of the Procedure for Preparing an Alloy Electrode, Cell Assembly and Cell Testing. The cells were cycled from 0.005 V to 0.90 V at specific rate of 75 mA/g-alloy with trickle down to 7.5 mA/g at the end of discharge (delithiation) for the first cycle. From then on, cells were cycled in the same voltage range but at 150 mA/g-alloy and trickle down to 15 mA/g-alloy at the end of discharge. Cells were allowed 15 min rest at open circuit at the end of every half cycle. Results are reported in Table 1 (below).
-
TABLE 1 Initial Capacity Capacity at Capacity at Loss, Cycle 2, Cycle 50, Efficiency Example percent mAh/g mAh/g percent 9 11 912 895 98 10 13 818 763 93 11 13 861 752 87 12 14 875 865 99 13 16 554 544 98 In Table 1 (above), Efficiency = Capacity at Cycle 50/Capacity at Cycle 2. - Overall, the alloy powders prepared according to the present disclosure, when fabricated into an electrode and further fabricated into a cell, showed stable capacity for many cycles, making them suitable for use as active anode materials in battery applications, including rechargeable lithium ion battery applications.
- All patents and publications referred to herein are hereby incorporated by reference in their entirety. All examples given herein are to be considered non-limiting unless otherwise indicated. Various modifications and alterations of this disclosure may be made by those skilled in the art without departing from the scope and spirit of this disclosure, and it should be understood that this disclosure is not to be unduly limited to the illustrative embodiments set forth herein.
Claims (18)
1. A method of making an alloy, the method comprising alloying components comprising:
a first ferrosilicon having a first ratio of iron to silicon; and
at least one of a metallic element or a metallic compound, wherein the alloy is substantially free of crystallites greater than 50 nanometers in size.
2. The method of claim 1 , wherein said metallic element or metallic compound comprises at least one of carbon, tin, titanium, zinc, iron, or silicon.
3. The method of claim 1 , wherein the alloy is amorphous.
4. The method of claim 1 , wherein alloying comprises milling using milling media.
5. The method of claim 1 , wherein the alloy comprises tin, iron, and silicon.
6. The method of claim 1 , wherein the alloy comprises tin, iron, and carbon.
7. The method of claim 1 , wherein the metallic compound comprises a second ferrosilicon having a second ratio of iron to silicon, and wherein the first ratio and the second ratio are different.
8. The method of claim 7 , wherein the components further comprise tin.
9. The method of claim 7 , wherein the components further comprise titanium.
10. The method of claim 1 , wherein the alloy is adapted for use as an active material in a negative electrode composition in a lithium ion battery.
11. The method of claim 10 , wherein said metallic element or metallic compound comprises at least one of carbon, tin, titanium, zinc, iron, or silicon.
12. The method of claim 10 , wherein the alloy is amorphous.
13. The method of claim 10 , wherein alloying comprises milling using milling media.
14. The method of claim 10 , wherein the alloy comprises tin, iron, and silicon.
15. The method of claim 10 , wherein the alloy comprises tin, iron, and carbon.
16. The method of claim 10 , wherein the components further comprise a second ferrosilicon having a second ratio of iron to silicon, and wherein the first ratio and the second ratio are different.
17. The method of claim 16 , wherein the components further comprise tin.
18. The method of claim 16 , wherein the components further comprise titanium.
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