Ni content of active cathode material is 80% or more. The limiting factors of Nirich NMC materials include structural and chemical instability in terms of material and electrode levels both before and during cycling. Increasing Ni content in the cathode can lead to an increase in cation mixing due to the similar size of Ni 2+ (0.69 Å) and Li + (0.76 Å). Migration of Ni 2+ into the Li vacancies further induces surface reconstruction from layered to inactive disordered spinel or rock-salt hindering lithium-ion diffusion. [4,5] During cycling at high voltage, the highly reactive Ni 4+ on the surface can generate parasitic reactions with liquid electrolyte, leading to continuous electrolyte consumption and safety issues. In addition, the removal of critical amounts of Li-ions from the Ni-rich materials could also create an accumulation of microstrains from caxis expansion/contraction which in turn cause microcracks and rapid capacity decay. [6] These challenges occur simultaneously and are needed to be addressed altogether.Two main strategies, i.e., surface coating and cation doping, have attracted the most attention in mitigating the issues of Ni-rich cathode. The surface coating can prevent direct contact between cathode active materials and a liquid electrolyte that can mitigate parasitic reactions, transition metal (TM) dissolution, and accommodate lattice expansion/contraction. [7][8][9][10][11][12] Conventional materials used for coating are Al 2 O 3 , [13,14] V 2 O 5 , [15] TiO 2 , [16] ZnO, [17] MgO, [18] and ZrO 2 . [19][20][21][22] Unfortunately, the sole inert metal oxide coating approach cannot solve all the intrinsic problems of NMC such as cation mixing, structural stability, and kinetic issues. [23] In case of the doping approach, cation dopants such as Mg 2+ , [24,25] Rb + , [26] and Zr 4+ , [11,27,28] serve as structural pillars that can enhance structural stability, Li + diffusion, and prevent rapid lattice expansion/collapse. [29,30] Doping with inactive ions can also modulate electron mobility in the materials, reduce cation mixing, avoid particle degradation, and improve thermal stability. However, cation doping may not be able to provide surface protection of active materials from HF scavenger and parasitic reactions with liquid electrolyte in conjunction with TM dissolution. [22] Among all metal oxides, ZrO 2 was widely used but its role is not yet fully understood.Herein, Ni-rich LiNi 0.8 Mn 0.1 Co 0.1 O 2 or NMC811 cathode material, which is expected to be widely used soon, is coated by crystalline ZrO 2 nanoparticles using green and scalable mechanofusion technique with an annealing process. A controllable synergistic effect of ZrO 2 coating, as a spherical coreshell morphology with low surface energy, which is ideal for the process of electrode fabrication, and Zr 4+ doping is carefully investigated. For the first time, the mechanofusion with the post-annealing at 800 °C used in this work can finely tune the shell thickness and doping gradient by the diffusion of Zr 4+ from the coated ZrO 2...