US lab uses nano-CT scans to breathe new life into dead EV batteries

Researchers at the US National Renewable Energy Laboratory (NREL) are employing ultra-high-resolution nano-computed tomography (nano-CT) scans to analyze and revive spent lithium-ion batteries from electric vehicles (EVs). This nondestructive imaging technique, capable of resolving features down to 50 nanometers, reveals microscopic cracks and internal defects in battery cathodes that traditional methods miss. These cracks, particularly in nickel-rich cathode particles, impede lithium-ion flow and degrade fast-charging capabilities despite retained energy capacity. By correlating structural damage with performance loss, the team can identify specific degradation patterns and tailor direct-recycling methods that refurbish rather than fully rebuild cathodes. The direct-recycling approach aims to repair damaged cathodes through gentler mechanical treatments that restore cracked particles or replace only damaged sections, preserving the crystal structure critical for high energy density. This method contrasts with conventional recycling, which dissolves electrodes into basic chemicals—an energy-intensive process that also risks losing valuable metals. Successful implementation would reduce processing