Electrodeposited Polyaniline on Steel Mesh: Experimental and Theoretical Insights for Zinc-Ion Batteries

The global shift toward renewable energy sources has heightened the need for energy storage systems that are not only efficient but also safe, scalable, and economically viable. Aqueous zinc-ion batteries (AZIBs) have gained attention as a promising candidate due to their low cost, nontoxicity, and operational safety. Nevertheless, the advancement of AZIB technology is hindered by the limited availability of robust cathode materials. This research presents a straightforward and scalable electrodeposition technique to develop a composite cathode consisting of polyaniline coated onto a stainless-steel mesh (PANI/SSM). The stainless-steel substrate enhances structural integrity and electrical conductivity, while the PANI layer facilitates redox activity and improves ion transport. Characterization techniques confirmed uniform PANI deposition and strong interfacial adhesion. Electrochemical evaluations revealed a specific capacity of 103 mAh/g at 0.2 A/g, with 70% capacity retention over 200 charge–discharge cycles, and favorable performance at various current rates. Impedance spectroscopy and cyclic voltammetry suggested efficient charge transfer and diffusion-governed kinetics. Additionally, density functional theory analysis highlighted the advantageous electronic features of PANI, underscoring its role in enhancing charge mobility. Overall, the PANI/SSM configuration presents a promising direction for the development of effective AZIB cathodes and supports future applications in eco-friendly energy storage solutions.