With the depletion of fossil fuel energy sources, air pollution and carbon emissions becoming more problematic, a transition to renewable energies is required. The most common renewable energy storage nowadays is lithium-ion batteries. However, those batteries cannot meet the requirement for the increasing demand in batteries of the growing market. Moreover, producing higher density batteries at a lower cost present safety issue due to the liquid electrolyte present in lithium-ion batteries.

All Solid-State Batteries were investigated to meet the market requirements, and to solve the safety issues presented by using liquid electrolytes. Solid State Thin-Film Batteries are promising power sources for micro devices due to their high safety, high energy density and easy integration with semiconductor processes. However, the conventional manufacturing methods of those thin films are vacuum-based and have a high cost and a low deposition efficiency which prevent the large-scale manufacturing of thin films as battery materials. Suspension Plasma Spraying and Atmospheric Plasma Spraying are two promising processes to manufacture thin film as battery components due to the versatility of materials for the substrate and their economic deposition process.

Therefore, the aim of this study is to investigate the possibility of utilizing thermal spray (TS) approaches to manufacture thin film battery components with desired characteristics as well as to explore the possibility of manufacturing multi-layer coatings to fabricate a complete Solid-State Thin Film Battery cell. The other aims of this study are to investigate the influence of spraying distance on the thin films manufactured with Suspension Plasma Spraying and Atmospheric Plasma Spraying and to analyse the influence of additives on suspension preparation.

During this thesis, porosity measurements, surface roughness measurement, elemental analysis, thickness measurement, deposition efficiency measurements, surface morphology analysis and cross section microstructure analysis have been performed. Three materials wereinvestigated LTO as an anode material, LLZO as an electrolyte material and NMC as a cathode material. Results showed that depending on the material, spraying distance can have an influence on the phase composition, the surface roughness, the elemental distribution, and the surface morphology of the samples.

The conclusion of this thesis is that Suspension Plasma Spraying and Atmospheric Plasma Spraying can manufacture double-layer (LTO/LLZO) coatings and triple-layer (LTO/LLZO/NMC) coatings. However further investigations are required regarding plasma spraying of thin film as battery components to achieve desired characteristics.