Because of the sustainability agreements, the need of minimizing the green house emission is demanded. One way is by change from combustion engines vehicle to electrical vehicles, leading to an increase in demand for rechargeable batteries. Most batteries today have liquid electrolyte, which is not only hazardous and toxic, but also dangerous since it is flammable and there is a risk of leakage due to short circuit or defects in the electrodes. Today’s solid-state batteries are having a difficult manufacturing route, creating not just cracks in the manufacturing but also during postprocessing, additionally it creates high rate of scarp since the coating are grinded and polished from 1 mm to 100 µm. Therefore, next generation of SSB’s need to be utilized: solid-state thin film batteries. Processes like vacuum deposition methods such as chemical vapor deposition, magnetron sputtering, and physical vapor deposition have been the leading techniques for manufacture thin films batteries. These processes have disadvantages that makes them unsuitable for large scale production.

Consequently, a new novel depositing technique needs to be developed. Researcher have been, during the last decades, seen that liquid feedstock thermal spray methods is a good candidate for thin films due to the nano-structured coating.

This thesis is a part of a project, with the aim of utilizing a novel approach tackling this difficulty and find an excellent solution for producing solid state thin-film batteries with thermal spray.

The objective of this thesis is to explore a novel coating strategy with suspension plasma spray for depositing electrode materials manufacture solid-state thin-film batteries.

This is performed with two electrode materials, deposited with a Mettech axial III suspension plasma spray. And investigated by microstructural characterization and exploring the phase constitutions. The result is showing that there are several process parameters impacting the microstructure and phase constitutions. The electrode material does degrade easily when exposed to heat and the plasma gasses appears to react with the material at elevated temperature. Except the enthalpy, the spray distance appears to have a great impact on the phase constitution. Extended test needs to be performed, but: The conclusion of this thesis is that suspension plasma spray is a candidate for depositing electrode materials, retaining the phase constitution.