Researchers at Hanyang University have uncovered a hidden manufacturing flaw that could shorten the lifespan of next-generation electric vehicle batteries. The team found that exposing battery precursor materials to air during storage can alter manganese on the surface of high-nickel cathodes, creating defects that accelerate battery degradation. These defects can trigger electrolyte breakdown and other harmful reactions inside the battery. In long-term cycling tests, affected batteries lost their capacity nearly twice as fast, potentially reducing the useful life of EV batteries. The researchers also found a simple way to prevent the problem: adding extra lithium during production helped stabilize the battery material and allowed it to retain more than 90% of its capacity. The findings could help manufacturers improve battery durability through better control of material storage and production processes, without requiring major changes to existing battery designs.
