Aluminium-based battery offers safer alternative to lithium-ion cells

Mumbai: A team of researchers in Bengaluru has developed a new battery technology that could offer a viable alternative to conventional lithium-ion batteries used in consumer electronics and electric vehicles. The innovation, led by scientists from the Centre for Nano and Soft Matter Sciences (CeNS) and the Centre for Nano Science and Engineering (CeNSE) at the Indian Institute of Science (IISc), uses aluminium and a water-based electrolyte to create a flexible, safe and environmentally friendly energy storage solution.

The research was carried out under the Department of Science and Technology (DST), Government of India. The battery is composed of copper hexacyanoferrate (CuHCFe) as the cathode and molybdenum trioxide (MoO₃) as the anode. The cathode is pre-filled with aluminium ions, which enables efficient energy storage and release. The use of aluminium – a widely available and recyclable metal – addresses concerns around the cost, safety and environmental impact of lithium extraction and processing.

Flexible Aqueous Aluminum-Ion Battery Concept: A visual overview of the battery design,
showing what it's made of, how it works, and how it stays reliable even when bent or flexed.
(Picture Courtesy - PIB)

One of the key advantages of the new battery is its mechanical flexibility. In laboratory tests, the device remained operational even when bent or folded, retaining 96.77% of its capacity after 150 charge–discharge cycles. Researchers demonstrated its performance by powering an LCD display while the battery was bent at extreme angles. This feature could be particularly useful in wearable electronics and foldable devices, where traditional rigid batteries limit design possibilities.

The battery’s aqueous electrolyte also contributes to its safety profile. Unlike lithium-ion batteries, which are prone to overheating and can pose fire hazards, the aluminium-based system is stable and non-flammable. This makes it suitable for applications where thermal management and user safety are critical.

The team employed advanced characterisation techniques, including electron microscopy and spectroscopy, to optimise the battery’s internal structure and validate its performance. The materials were engineered at the microscopic level to overcome longstanding challenges in aluminium battery chemistry, such as ion mobility and electrode compatibility.

While the technology is still in the research phase, the results suggest that aluminium-ion batteries could be scaled for broader use in portable electronics, electric mobility and other energy storage applications. The work represents a significant step forward in multivalent ion battery research, which seeks to develop alternatives to lithium-based systems by using ions with higher charge densities.

The development aligns with India’s broader goals of promoting sustainable technologies and reducing dependence on imported raw materials. By leveraging abundant domestic resources and focusing on safety and recyclability, the research contributes to the country’s efforts to build a resilient and environmentally responsible energy infrastructure.