Double-Shelled Fe-Fe₃C Nanoparticles Embedded on a Porous Carbon Framework for Superior Lithium-Ion Half/Full Batteries

Cost-effective and environmentally friendly Fe-based active materials offer exceptionally high energy capacity in lithium-ion batteries (LIBs) due to their multiple electron redox reactions. However, challenges, such as morphology degradation during cycling, cell pulverization, and electrochemical stability, have hindered their widespread use. Herein, we demonstrated a simple salt-assisted freeze-drying method to design a double-shelled Fe/Fe3C core tightly anchored on a porous carbon framework (FEC). The shell consists of a thin Fe3O4 layer (approximate to 2 nm) and a carbon layer (approximate to 10 nm) on the outermost part. Benefiting from the complex nanostructuring (porous carbon support, core-shell nanoparticles, and Fe3C incorporation), the FEC anode delivered a high discharge capacity of 947 mAh g(-1) at 50 mA g(-1) and a fast-rate capability of 305 mAh g(-1) at 10 A g(-1). Notably, the FEC cell still showed 86% reversible capacity retention (794 mAh g(-1) at 50 mA g(-1)) at a high cycling temperature of 80 degrees C, indicating superior structural integrity during cycling at extreme temperatures. Furthermore, we conducted a simple solid-state fluorination technique using the as-prepared FEC sample and excess NH4F to prepare iron fluoride-carbon composites (FeF2/C) as the positive electrode. The full cell configuration, consisting of the FEC anode and FeF2/C cathode, reached a remarkable capacity of 200 mAh g(-1) at a 20 mA g(-1) rate or an energy density of approximately 530 Wh kg(-1). Thus, the straightforward and simple experimental design holds great potential as a revolutionary Fe-based cathodic-anodic pair candidate for high-energy LIBs.