As the global demand for lithium-ion batteries continues to surge, the pressure to ensure higher quality, safer, and more reliable battery components has never been greater.
In this interview, experts from Thermo Fisher Scientific present innovative analytical solutions to identify and control impurities in battery raw materials and electrolytes. From scanning electron microscopy (SEM) and energy-dispersive X-ray spectroscopy (EDS) to robust ICP-OES (inductively coupled plasma optical emission spectroscopy) methods, the panel discusses how automation, trace element analysis, and standardized workflows are transforming quality control.
The three speakers—Eduardo Sardinha, Tomoko Vincent, and Sukanya Sengupta—explore how their tools are helping battery manufacturers stay ahead of industry demands.
Eduardo, why is impurity analysis such a critical part of battery quality control today?
Eduardo Sardinha: Impurities like copper, iron, and zinc, even in tiny amounts, can cause significant issues in battery cells. We're talking about risks ranging from performance degradation to serious safety hazards like overheating and fires. For example, particles larger than 10 µm can penetrate separators and cause short circuits. Even smaller ones can dissolve and migrate, disrupting the SEI layer. So, early detection is absolutely vital.
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How does SEM, combined with EDS, help pinpoint those impurities?
Eduardo Sardinha: SEM provides detailed morphological information, while EDS provides the chemical composition. When you automate this with software, you can get high-throughput, standardized impurity classification that is completely user-independent. That means no manual bias and faster, more reliable data. It’s especially useful in production settings where repeatability is key.
Tomoko, your presentation focused on trace metal analysis in brine. What makes brine so difficult to analyze?
Tomoko Vincent: Brine is complex because it's a high-matrix sample with extremely variable lithium concentrations, from 10 ppm to 4000 ppm. It can clog instruments and introduce spectral interferences. We used a 25 % brine matrix in our study, which is quite aggressive, but with the right setup—ceramic torch, MiraMist nebulizer, and matrix-matched standards—we maintained excellent sensitivity and reproducibility for over 11 hours of continuous analysis.
What were the key takeaways from that robustness test?
Tomoko Vincent: We ran 210 samples in a single sequence without maintenance, and the internal standard recovery stayed between 90% and 110%. That’s a testament to how reliable and efficient this ICP-OES setup can be for demanding battery-grade lithium brine applications.
Sukanya, you worked on electrolyte analysis. What makes lithium hexafluorophosphate (LiPF₆) analysis unique?
Sukanya Sengupta: LiPF6 electrolytes are tricky because they contain organics and HF from partial hydrolysis. These components pose stability issues for the plasma in ICP-OES and contribute to the spectral background. We had to optimize every detail—from the torch to the spray chamber and nebulizer. In the end, we were able to consistently detect 15 trace elements well below the required 1 ppm regulatory limits, even in complex matrices.
Did you find any particularly challenging elements to quantify?
Sukanya Sengupta: Arsenic and lead are usually difficult to quantify due to low detection limits and interference, but we were able to achieve excellent results.The high resolution and full-frame detection capabilities of ICP-OES made a big difference, allowing precise peak selection and minimal spectral overlap.
Eduardo, can you give us an example of how software can enhance reporting and decision-making?
Eduardo Sardinha: Absolutely. Advanced custom software lets users automatically generate detailed, customizable reports. You can set pass/fail thresholds, create histogram plots based on size and chemistry, and even isolate specific particles like copper or iron.
It’s all about getting actionable insights fast, especially in high-throughput manufacturing environments.
What’s the broader message for battery manufacturers looking to improve quality control?
Sukanya Sengupta: Prioritize accuracy and reproducibility. Whether you're working with raw materials, slurries, or finished electrolytes, having robust, automated workflows will save time, reduce errors, and ultimately improve battery performance and safety.
Tomoko Vincent: And don’t underestimate the value of trace-level insights. What might seem like a tiny contaminant can have a massive downstream effect.
Eduardo Sardinha: I would also say that you should choose to invest in scalable, flexible systems. Whether you’re testing at pilot scale or ramping up to full production, the right tools can grow with you.
Watch the Accompanying Webinar: Comprehensive Metal Impurity Analysis in Battery Manufacturing
About the Speakers
Eduardo Sardinha, Application Scientist, Thermo Fisher Scientific
Eduardo specializes in scanning electron microscopy (SEM) and EDS analysis. His work focuses on battery material characterization, particularly the automated detection of impurities using SEM workflows to ensure product quality and safety in high-volume manufacturing environments.
Tomoko Vincent, Application Scientist, Thermo Fisher Scientific
Tomoko brings extensive experience in inductively coupled plasma optical emission spectroscopy (ICP-OES), with a focus on trace metal analysis in complex matrices such as lithium brines. Her work emphasizes robust, high-throughput solutions for quality control in battery production.
Sukanya Sengupta, Application Scientist, Thermo Fisher Scientific
Sukanya's expertise lies in elemental analysis using ICP-OES, especially in battery electrolyte applications. She has developed sensitive, interference-free methods for analyzing trace contaminants in challenging organic matrices to support battery quality assurance and regulatory compliance.
This information has been sourced, reviewed and adapted from materials provided by Thermo Fisher Scientific.
For more information on this source, please visit thermofisher.com/battery-solutions.
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