Cobalt’s Vital Role in Lithium-ion Batteries and Beyond

What is Cobalt and Why is it Important?

Cobalt, a silvery-white transition metal, has emerged as one of the most crucial elements in our modern technological landscape. While it may not have the name recognition of gold or silver, this metallic element plays a pivotal role in enabling the green energy transition and supporting advanced technologies that define our current era.

Despite being relatively rare in the Earth's crust (only about 25 parts per million), cobalt's unique properties make it invaluable across multiple industries. From powering electric vehicles to enabling supercomputers, cobalt has become indispensable in our increasingly electrified world.

The Strategic Importance of Cobalt

Cobalt's strategic significance cannot be overstated, particularly in today's rapidly evolving technological landscape:

• Battery Technology: Cobalt serves as a critical component in lithium-ion batteries, enabling higher energy density and stability for electric vehicles and portable electronics.

• Aerospace Applications: In superalloys, cobalt enhances high-temperature strength and creep resistance, making jet engines and gas turbines more efficient and reliable.

• Industrial Manufacturing: As a binding agent in cemented carbides, cobalt creates cutting tools that maintain precision under extreme conditions.

• Clean Energy Transition: Cobalt plays a foundational role in renewable energy storage systems, helping stabilize electrical grids powered by intermittent sources like solar and wind.

• National Security: Many countries classify cobalt as a "critical mineral" due to its concentrated supply chain and essential role in defence critical materials.

As Shanghai Metal Market noted in their July 2025 analysis, "Cobalt's role in clean energy is irreplaceable. Its high-temperature stability and magnetic properties make it indispensable for EVs and aerospace."

Key Properties That Make Cobalt Valuable

Cobalt's position in the periodic table (element 27) gives it unique characteristics that few other elements can match:

• Temperature Resilience: Maintains structural integrity and properties at extremely high temperatures (above 1000°C in some applications).

• Magnetic Excellence: Creates some of the strongest permanent magnets when alloyed with samarium and other rare earth elements.

• Binding Capabilities: Cobalt's electron configuration ([Ar] 3d⁷ 4s²) enables exceptional metallic bonding in alloys and composites.

• Catalytic Efficiency: Facilitates critical chemical reactions in petroleum refining and various industrial processes.

• Color Stability: Produces vibrant, stable blue pigments that have been used since ancient times (as seen in Ming Dynasty porcelain preserved in the British Museum).

Perhaps most remarkably, cobalt is also biologically essential—it forms the central atom in vitamin B12 (cobalamin), which is crucial for human health and cellular function.

How Does Cobalt Function in Lithium-ion Batteries?

The most significant commercial application of cobalt today is in lithium-ion batteries, where it plays a crucial role in the cathode material. Understanding the role of cobalt in lithium-ion batteries and its applications helps explain why it remains difficult to eliminate despite ongoing research into alternatives.

At the atomic level, cobalt provides stability to the layered oxide crystal structure that makes lithium-ion cathodes work efficiently. This stabilization enables the consistent flow of lithium ions during charging and discharging cycles—the fundamental process that powers everything from smartphones to electric vehicles.

The Critical Role in Battery Cathode Materials

In lithium-ion batteries, cobalt performs several essential functions that directly impact battery performance:

• Structural Stabilization: Cobalt ions (Co³⁺) in the crystal lattice prevent oxygen release during charge/discharge cycles, significantly improving safety profiles.

• Energy Density Enhancement: NMC (nickel-manganese-cobalt) cathodes with appropriate cobalt content can achieve 20-30% higher energy density than cobalt-free alternatives.

• Thermal Management: Cobalt-containing cathodes decompose at higher temperatures (approximately 210°C versus 180°C for some cobalt-free materials), providing a critical safety margin.

• Cycle Life Extension: The presence of cobalt can extend battery lifespan by 30-40% by preventing structural collapse during repeated charge cycles.

• Power Delivery Optimization: Cobalt enhances lithium-ion diffusion rates by approximately 40%, allowing for faster charging and higher power output.

According to SMM's Technical Analysis (July 2025), "Cobalt stabilizes layered oxide cathodes, preventing oxygen release during thermal runaway. Complete elimination compromises safety in high-energy-density applications."

Technical Challenges in Reducing Cobalt Content

While manufacturers strive to reduce cobalt content due to supply concerns and cost considerations, several technical hurdles remain:

• Energy Density Trade-offs: NMC811 batteries (8 parts nickel, 1 part manganese, 1 part cobalt) contain only 5% cobalt compared to 20% in older NMC111 formulations, but this reduction comes with engineering challenges.

• Safety Considerations: Complete cobalt elimination often leads to thermal instability in high-energy-density applications, particularly under fast-charging conditions.

• Performance Degradation: Low-cobalt formulations typically exhibit reduced cycle life in demanding applications like electric vehicles.

• Scientific Consensus: Materials scientists generally agree that while cobalt content can be reduced, complete elimination in high-performance applications requires significant breakthroughs.

• Premium Market Requirements: High-end electric vehicles and aerospace applications continue to use cobalt-containing batteries where performance outweighs cost considerations.

Market Dynamics Driving Cobalt Demand

The explosive growth of electric vehicles represents the primary driver of cobalt demand:

• EV Production Acceleration: Global EV manufacturing is projected to require 350,000 tonnes of cobalt annually by 2030 (Cobalt Institute, 2025).

• Energy Storage Growth: Grid-scale battery installations are expanding at 35% CAGR, creating additional demand for high-stability cathodes.

• Consumer Electronics Evolution: Higher-capacity smartphones, laptops, and wearables require cobalt-containing batteries for their combination of safety and energy density.

• Strategic Considerations: Many manufacturers maintain dual-sourcing strategies, using cobalt-containing batteries for premium products and cobalt-free options for entry-level offerings.

Tesla's approach exemplifies this strategy—their Model 3 Long Range uses NCA (nickel-cobalt-aluminum) cathodes containing approximately 3.5% cobalt, while their standard range vehicles increasingly utilize cobalt-free LFP (lithium iron phosphate) chemistry. However, the industry is constantly evolving with Australia lithium innovations and recent battery recycling breakthrough technologies changing the landscape.

Why is Cobalt Essential for Aerospace and Energy Applications?

Beyond batteries, cobalt plays a critical role in high-temperature applications where reliability is paramount. The aerospace and energy generation sectors rely on cobalt-containing superalloys to withstand extreme conditions that would cause conventional materials to fail.

These superalloys—primarily nickel-based with significant cobalt content—enable jet engines, gas turbines, and other high-temperature components to operate efficiently and safely for thousands of hours under tremendous stress.

Superalloy Performance Enhancement

Cobalt contributes several crucial properties to superalloys used in aerospace and energy applications:

• High-Temperature Strength: Superalloys containing 5-20% cobalt maintain structural integrity at temperatures up to 1,200°C—approximately 250°C higher than cobalt-free alternatives.

• Creep Resistance: Cobalt reduces stacking fault energy in nickel-based alloys, preventing deformation under sustained high-temperature stress.

• Thermal Fatigue Resistance: The addition of cobalt significantly improves material performance during rapid heating and cooling cycles, crucial for jet engines during takeoff and landing.

• Oxidation Protection: Cobalt contributes to the formation of protective oxide layers (particularly CoCr₂O₄ spinels) that prevent further oxidation at high temperatures.

• Corrosion Mitigation: In marine and industrial turbines, cobalt enhances resistance to hot corrosion from sulfur, sodium, and other contaminants.

According to SMM's Materials Science Review (July 2025): "Cobalt's solid-solution strengthening in γ'-Ni₃Al phases is critical for turbine blade creep resistance. No substitute matches its performance in >1,000°C environments."

Critical Applications in Advanced Engineering

The aerospace and energy sectors rely on cobalt-containing superalloys for their most demanding components:

• Jet Engine Turbine Blades: First-stage turbine blades in commercial aircraft engines (like GE9X used in the Boeing 777X) contain approximately 5-12% cobalt.

• Combustion Chambers: The hottest sections of jet engines utilize cobalt-containing alloys to withstand extreme combustion temperatures.

• Guide Vanes: These components direct hot gas flow and must maintain precise geometry under severe thermal stress.

• Military Propulsion Systems: Advanced fighter engines like Pratt & Whitney's F135 (used in the F-35) utilize MAR-M-247 alloy containing 12% cobalt.

• Power Generation Turbines: Siemens Energy's H-class gas turbines achieve 64% efficiency partly due to cobalt-containing high-temperature components.

Each GE9X engine contains approximately 5 tonnes of cobalt-containing superalloys, highlighting the substantial material requirements for modern aerospace applications.

Future Development Trajectory

The future of aerospace and energy generation will likely increase—not decrease—reliance on cobalt:

• Rising Operating Temperatures: Next-generation engines aim to increase efficiency by operating at higher temperatures, requiring even more sophisticated cobalt-containing alloys.

• Efficiency Mandates: Regulatory pressure to reduce carbon emissions drives turbine development toward higher operating temperatures where cobalt provides critical performance benefits.

• Advanced Materials Development: Research into Co-Re-Cr systems aims to enable 1,300°C turbine operation, potentially increasing cobalt content in critical components.

• Reliability Requirements: As service intervals extend (modern jet engines now operate 30,000+ hours between overhauls), the importance of cobalt's contribution to long-term material stability increases.

• Specialized Applications: In nuclear power, aerospace, and defence sectors, performance and reliability requirements outweigh material cost considerations.

How Does Cobalt Strengthen Industrial Manufacturing?

The manufacturing sector relies heavily on cobalt as a binding agent in cemented carbides, creating cutting tools that literally shape our modern world. From precision machining to mining operations, these cobalt-bonded tools enable the production of everything from smartphone components to tunnel boring machines.

Cemented carbides (often called "tungsten carbide" or "carbide") combine extremely hard tungsten carbide (WC) particles with a softer cobalt binding phase to create a composite material with an exceptional balance of hardness and toughness.

The Binding Mechanism in Cemented Carbides

Cobalt performs a unique role in the creation of cemented carbides:

• Liquid-Phase Sintering: During manufacturing, cobalt melts at 1,495°C and flows between tungsten carbide grains, creating a continuous metallic binding network.

• Optimal Concentration Range: Industrial applications typically use 6-12% cobalt content, precisely balancing hardness and fracture resistance.

• Microstructural Control: The cobalt binder forms a "web" that surrounds individual tungsten carbide grains, preventing catastrophic crack propagation.

• Interface Chemistry: Cobalt partially dissolves tungsten and carbon during sintering, creating strong chemical bonds at particle interfaces.

• Grain Size Regulation: The cobalt percentage directly influences the final grain size and distribution, which determines tool performance characteristics.

As SMM's Industrial Applications Report (July 2025) explains: "Cobalt's liquid-phase sintering creates a ductile 'binder web' that prevents catastrophic WC grain pullout. This is non-negotiable for mining drill bits."

Performance Benefits in Industrial Applications

The cobalt binder phase contributes several critical performance characteristics:

• Toughness Regulation: Cemented carbides with 10% cobalt exhibit approximately 1,800 MPa fracture toughness, making them resistant to chipping during interrupted cutting.

• Impact Resistance: The ductile cobalt phase absorbs energy during impact, preventing brittle failure under sudden loads.

• Wear Resistance Maintenance: While cobalt is softer than tungsten carbide, the composite structure maintains exceptional wear resistance through the secure anchoring of hard particles.

• Thermal Stability: Cobalt-bonded carbides maintain their properties at the high temperatures generated during high-speed machining.

• Reliability Under Pressure: The cobalt binding phase prevents premature tool failure, extending service life in demanding applications.

Wide-Ranging Industrial Applications

Cobalt-bonded tungsten carbide tools enable numerous critical industrial processes:

• Precision Metal Machining: Carbide cutting tools are essential for manufacturing automotive components, aerospace parts, and consumer electronics.

• Mining Operations: Drill bits containing 7-9% cobalt penetrate the hardest rock formations for mineral extraction and tunnel construction.

• Oil and Gas Extraction: Sandvik's TSP drill bits (7% Co) increase oil-well drilling speed by 30% and extend service life in abrasive formations.

• Infrastructure Development: Herrenknecht tunnel boring machines (TBMs) use cobalt-bonded cutters for major projects like the Channel Tunnel.

• Die Casting and Forming: Wear-resistant molds and dies for metal forming operations rely on cobalt-bonded carbides to maintain dimensional precision.

The global cemented carbide market, valued at approximately $26 billion in 2025, remains 75% dependent on cobalt binders despite ongoing research into alternatives. This ongoing demand has contributed to the Halls Creek cobalt expansion project.

What Other Applications Benefit from Cobalt's Properties?

Beyond batteries, superalloys, and cemented carbides, cobalt's unique properties make it valuable across numerous specialized applications. These diverse uses highlight cobalt's versatility and explain why it's considered a truly critical element in modern technology.

High-Performance Permanent Magnets

Samarium-cobalt (Sm-Co) magnets represent one of cobalt's most sophisticated applications:

• Exceptional Magnetic Strength: Sm-Co magnets generate energy products up to 32 MGOe, significantly outperforming conventional ferrite magnets (20 MGOe).

• Temperature Stability: Unlike neodymium magnets, Sm-Co maintains 85% of its magnetic strength at temperatures above 300°C—critical for aerospace and industrial applications.

• Corrosion Resistance: Sm-Co magnets don't require protective coatings in harsh environments, simplifying design for marine and aerospace uses.

• Radiation Hardness: These magnets maintain performance under radiation exposure, making them ideal for space applications and medical equipment.

• Precision Applications: High-end sensors, measurement devices, and scientific instruments rely on the stability of Sm-Co magnets.

NASA's Perseverance Mars rover uses Sm-Co motors in critical mechanisms where reliability in extreme conditions is essential. As SMM's Advanced Materials Analysis (July 2025) notes: "Sm₂Co₁₇ magnets maintain 85% magnetic strength at 400°C—critical for satellite gyroscopes. No alternative matches this temperature resilience."

Pigments and Colorants

Cobalt compounds produce some of the most vibrant and stable blue and green pigments available:

• Color Stability: Cobalt blue (CoAl₂O₄) maintains its brilliant hue under intense UV exposure and extreme temperatures.

• Heat Resistance: Ceramic pigments containing cobalt withstand kiln temperatures exceeding 1,200°C without degradation.

• Chemical Inertness: Cobalt pigments resist chemical attack from acids, bases, and solvents, making them ideal for industrial coatings.

• Historical Significance: Cobalt blue has been used in fine art for centuries, appearing in masterpieces from Renaissance paintings to BMW's cobalt-blue i8 supercar.

• Modern Applications: Beyond ceramics and fine art, cobalt pigments appear in high-end cosmetics, architectural coatings, and specialty glass.

The cobalt blue pigment market alone represents approximately $280 million annually (2025), growing at 5.2% CAGR as premium applications expand.

Catalytic Applications

Cobalt's ability to facilitate chemical reactions makes it invaluable in several industrial catalytic processes:

• Petroleum Refining: Co-Mo/Al₂O₃ catalysts enable hydrodesulfurization, reducing diesel sulfur content to below 10 ppm to meet environmental regulations.

• Clean Fuel Production: Cobalt catalysts remove harmful nitrogen and sulfur compounds from fossil fuels, reducing air pollution.

• Polymer Manufacturing: Cobalt acetate catalyzes the production of terephthalic aci

Ready to Spot the Next Major Mineral Discovery?

Don't miss out on significant ASX mineral discoveries as they happen – Discovery Alert's proprietary Discovery IQ model provides instant, actionable alerts on potential opportunities, giving you a market-leading advantage. Explore why major mineral discoveries can lead to substantial returns by visiting our dedicated discoveries page and begin your 30-day free trial today.