Research by American scientists has illuminated reasons for the faster-than-expected aging of some modern electric vehicle batteries. Parallel studies in China are also underway, focusing on restoring the performance of used lithium-ion batteries.
Findings from Argonne National Laboratory and the University of Chicago revealed that internal mechanical stresses, caused by uneven electrochemical reactions, are the primary reason for capacity loss and cracking in high-nickel monocrystalline cathode batteries. This contradicts earlier assumptions that monocrystalline structures inherently guarantee longer lifespans, as it was traditionally believed that these cathodes lack grain boundaries, known to be crack sources in polycrystalline materials.
Meanwhile, Chinese researchers are reporting laboratory methods for restoring the capacity of used electric vehicle batteries. In the second half of 2025, scientists from Huazhong University of Science and Technology presented a regeneration technology for high-nickel lithium-ion battery cathodes using salt melt. According to published data, this process can restore up to 76% of the initial discharge capacity of degraded materials, enabling lithium ions to re-enter damaged crystal structures and eliminating structural defects caused during extended operation.
The study showed that many spent cathodes of electric vehicle batteries retain sufficient structural integrity for material-level regeneration. This positions high-nickel cathodes as promising research subjects for restoration efforts, especially given the rapid growth of China’s electric vehicle battery recycling market. Consequently, there is an expected significant increase in disused batteries in China, creating favorable conditions for the development of regeneration and recycling.
Moreover, in 2025, an academic study on regeneration strategies for spent lithium iron phosphate (LFP) batteries utilizing redox reactions was conducted in China. An overview by scholars from the Jiangsu Normal University and their colleagues systematizes regeneration methods based on oxidation and reduction, describing ways to optimize recycled cathode materials and emphasizing the need for further research into different chemical compositions.
Market analysis indicates that the Chinese lithium-ion battery recycling and reuse industry encompasses an entire supply chain. This includes battery and raw materials recycling companies (CATL, BYD, Shanxi Coking, Yunnan Tin), companies specializing in recycling and chemical processing (Huayou Cobalt, New Energy Zhongneng, Ganfeng Lithium, Haopeng Technology), alongside battery materials and metal powder manufacturers (Dangsheng Technology, Heyuan Fuma).
The results of American research on monocrystalline battery aging and Chinese developments in regeneration show that understanding material-level mechanisms and applying laboratory recovery methods are significant for extending electric vehicle battery lifespans. Market analysis points to growing volumes of disused electric vehicle batteries entering the Chinese market. Studies also consider economic factors, such as cobalt use and alternative chemical compositions, important for the potential industrial adoption of regeneration technologies.
