In Situ Carbothermic Reduction of Black Mass from Spent Li-Ion, Ni-MH, and Alkaline Batteries for Ni-Based Superalloy Synthesis

Superalloys are widely recognized as ideal materials for high-temperature structural applications. Traditionally, these alloys have been manufactured from mined metal by using conventional alloying techniques. In this proof-of-concept study, we successfully made a Ni-based superalloy from waste batteries through a single-step selective in situ reduction technique bypassing the conventional norms of superalloy production. Spent batteries from obsolete electronic products and electric vehicles represent a valuable resource, as they house critical metals and minerals (e.g., Co, Ni, Mn, Graphite, and REEs) essential for superalloy production. We recycled these critical metals and minerals from spent batteries and made a Ni-based superalloy. Beyond contributing to responsible material consumption, the comprehensive compositional and structural profiling reveals that this superalloy exhibits potential for oxidative, corrosive, and various structural applications, attributed to its distinctive γ/γ' nanostructure. This cutting-edge study outlines a strategic method for creating superalloys from waste batteries, decreasing the need for traditional mining and alloying.