Robust All-Solid-State Batteries with Sodium Ion Electrolyte, Aluminum and Additive Manufacturing Inconel 625 Electrodes.

This study investigates all-solid-state batteries employing multifunctional metallic current collectors/electrodes that remain electrochemically inert toward an alkali-based Na ion solid electrolyte. Inconel 625 was evaluated as the positive current collector in combination with aluminum as the negative electrode and the ferroelectric electrolyte Na2.99Ba0.005OCl. The inertness of both electrodes enabled the construction of a robust device architecture that behaved as a true battery, exhibiting a two-phase equilibrium discharge plateau at ~1.1 V despite the absence of traditional Faradaic reactions. After a one-month rest period, the cell was sequentially discharged through external resistors and retained full functionality for one year. Cyclic voltammetry confirmed a stable electrochemical response over repeated cycling. The final long-term discharge under a 9.47 kΩ load produced a steady ~0.92 V plateau and delivered a total capacity of 35 mAh (~2.3 mAh·cm-2). Post-mortem analyses revealed excellent chemical and mechanical stability of Inconel 625 after extended operation, while aluminum showed superficial surface degradation attributed to residual moisture, with X-ray diffraction indicating the formation of aluminum hydroxide. Scanning Kelvin probe measurements guided electrode selection and provided insight into interfacial energetics, whereas scanning electron microscopy confirmed interface integrity. Complementary density functional theory simulations optimized the crystalline bulk and surfaces of Inconel, demonstrating interfacial stability at the atomic scale. Overall, this work elucidates the fundamental driving forces underlying traditional battery operation by studying a "capacity-less" system, highlighting the central role of interfacial electrostatics in sustaining battery-like discharge behavior in the absence of redox-active electrodes.