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Ultrasonic Welding Creates Lithium–Garnet Interface in Seconds

Bonding lithium metal to a ceramic surface should be a dream team combination for creating solid-state lithium metal batteries. However, getting them to bond is the hard part. Impurity layers tend to form on the surface, which hinders a process called wetting that is crucial to the adherence of metals and ceramics. To get these two materials with very different characteristics to bond, a different strategy was needed. Researchers at Tohoku University’s Advanced Institute for Materials Research (WPI-AIMR) thought outside the box, finding that ultrasonic welding brought these two materials together.

“This is an underexplored method in our field. Applying ultrasonic welding to bond lithium metal directly to a garnet-type oxide electrolyte is, to our knowledge, unprecedented in this context,” remarks Eric Jianfeng Cheng (WPI-AIMR).

The research describing this exciting new implementation strategy – which may help create more efficient and practical solid-state energy storage technology than conventional lithium-ion batteries – was published in Small Structures on March 19, 2026.

Solid-state lithium metal batteries are widely regarded as a promising next-generation energy storage technology. Among solid electrolytes, the garnet-type oxide Li₇La₃Zr₂O₁₂ (LLZO) has attracted particular attention because of its high ionic conductivity and chemical stability. However, establishing intimate physical contact between lithium metal and the ceramic electrolyte (Li₇La₃Zr₂O₁₂ or LLZO) is difficult. The stiff, irregular shapes of a marble slab and a metal sheet interface are challenging to bond mainly because both surfaces readily form insulating Li₂CO₃ layers when exposed to air. This occurs for the Li metal surface in particular and creates a barrier of sorts that blocks Li-ion transport and hinders wetting.

Ultrasonic welding (USW), a mature industrial technique widely used for joining metallic components, offers a solution that is fundamentally different from conventional strategies (which are costly and process-intensive). The results of this study demonstrate that USW can form intimate lithium–LLZO interfaces within seconds at room temperature. The ultrasonic vibration disrupts insulating surface layers such as Li₂CO₃, while controlled pressure and high-frequency oscillation enable lithium metal to plastically deform and conform to the rigid LLZO surface, eliminating interfacial voids and establishing direct solid-state contact without melting or thermal activation.

Using USW alone, the interfacial resistance was reduced to approximately 225 Ω·cm². When combined with a thin sputtered Au interlayer, the resistance further decreased to about 1.5 Ω·cm², placing it among the lowest values reported for room-temperature processed Li–LLZO interfaces. Symmetric cell testing confirmed its practical feasibility as well.

This rapid, room-temperature bonding strategy provides a manufacturing-friendly and efficient pathway for oxide-based solid-state batteries. This work contributes to the development of safer and higher-energy batteries for electric vehicles, renewable energy storage, and portable electronics.

The findings were published in Small Structures on March 19, 2026.

Publication Details

Title:	Ultrasonic Welding of Garnet Solid Electrolytes to Lithium Metal: Achieving Intimate Interfacial Contact in Seconds
Authors:	Mikihisa Fukuda, Ying Li, Run-Zi Wang, Shin-ichi Orimo, Yutaka S. Sato, Hidemi Kato, Eric Jianfeng Cheng
Journal:	Small Structures
DOI:	10.1002/sstr.202500866

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