Issue

Vol. 18 (2026)

Electrochemical Corrosion and Safety Hazards in Sustainable Batteries: Corrosion Mechanisms, Safety Challenges, and Protection

https://doi.org/10.1007/s40820-026-02178-9
Chandrabhan Verma
Department of Chemical and Petroleum Engineering, Khalifa University of Science and Technology, P.O. Box 127788, Abu Dhabi, United Arab Emirates
Imad Barsoum
Emirates Nuclear Technology Center (ENTC), Khalifa University, 12788 Abu Dhabi, United Arab Emirates
Akram Alfantazi
Department of Chemical and Petroleum Engineering, Khalifa University of Science and Technology, P.O. Box 127788, Abu Dhabi, United Arab Emirates
Kyong Yop Rhee
Department of Mechanical Engineering, College of Engineering, Kyung Hee University, Yongin 445‑701, South Korea

Corresponding Author: Kyong Yop Rhee

rheeky@khu.ac.kr

Nano-Micro Letters, Vol. 18 (2026), Article Number: 331

Abstract

The swift transition to sustainable energy has heightened demand for high-performance, safe, and environmentally responsible battery technologies. Zn₋, Mg₋, Na₋, Al₋, Fe₋, organic, and bio-based systems offer several advantages over traditional resource-intensive and toxic alternatives. However, their practical implications are significantly challenged by their susceptibility to electrochemical corrosion, which adversely affects their efficiency, longevity, safety, recyclability, and reversibility. Corrosion is one of the most significant and persistent barriers to the development of next-generation energy storage systems. This review comprehensively presents unified mechanisms of corrosion across diverse sustainable battery systems, with a detailed account of pitting, uniform, galvanic, intergranular, and passivation-related degradation pathways. The article presents a unique comparison of the degradation mechanisms of Zn, Al, Mg, and other anodes in different electrolytes. Corrosion mitigation strategies, including surface passivation, surface engineering, alloying, use of surfactants and polymer-based films, ionic liquids, deep eutectic solvents, metal–organic frameworks, heterocycles, and bio-based multifunctional corrosion inhibitors, have been comprehensively surveyed. These inhibitors suppress the increase in cycle life, achieving inhibition efficiencies of over 90%. Lastly, the review highlights the design of molecular-level corrosion inhibitors, interfacial engineering, real-time corrosion testing, advanced electrolytes, and forward-looking directions, all of which are essential to the development of sustainable, stable energy storage systems.


Highlights:
1 This review provides the first comprehensive collection of electrochemical corrosion mechanisms in Zn-, Al-, Mg-, Na-, organic-, and bio-based batteries, highlighting their safety and hazardous effects of corrosion in sustainable batteries.
2 This review uniquely presents the connection of electrochemical corrosion with dendrite formation, hydrogen evolution, impedance growth, recycling challenges, capacity fading, and safety hazards.
3 This provides a next-generation solution, such as corrosion inhibitors, bio-derived additives, metal–organic frameworks, deep eutectic solvents, ionic liquids, gel electrolytes, and interfacial and surface engineering approaches.

Keywords

Electrochemical corrosion Sustainable energy storage Metal-anode batteries Interfacial engineering Corrosion inhibitors
Verma, Chandrabhan, Imad Barsoum, Akram Alfantazi, and Kyong Yop Rhee. 2026. “Electrochemical Corrosion and Safety Hazards in Sustainable Batteries: Corrosion Mechanisms, Safety Challenges, and Protection”. Nano-Micro Letters 18 (April):331. https://doi.org/10.1007/s40820-026-02178-9.
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