Nanosized alloy-type materials (Si, Ge, Sn, etc.) present
superior
electrochemical performance in rechargeable batteries. However, they
fail to guarantee cycling capacity and stability under high mass loading
required by industrial applications due to low electric contact and
adhesive strength, which has long been a challenge. This work proposes
a rational design for an alloy-type anode via facile and versatile
laser microcladding and dealloying. The proposed anode features a
large-area porous network composed of continuous nano-ligaments, which
consist of evenly distributed nanosized alloy-type material metallurgically
bonded with conductive material. The fabrication of the structure
is validated using Ge–Cu and Sn–Cu anodes, both exhibiting
enhanced cycling stability at high areal capacity and rate performance
in lithium-ion batteries. The enhancement is attributed to the structural
features, which contribute to lithiation–delithiation stability
and intact electron/Li ion transference path, as verified by in situ
and ex situ transmission electron microscopy observations. More importantly,
the critical solidification conditions of laser microcladding are
provided by a multiphysics simulation, allowing for a thorough understanding
of the structural formation mechanism. The study provides a possible
approach to improve mass loading and performance of an alloy-type
anode for practical application.