Sulfide-based solid electrolytes (SEs), including Li3PS4 (314), Li6PS5Cl (615), and Li7P3S11 (7311), offer high ionic conductivities suitable for all-solid-state batteries (ASSBs), yet suffer from intrinsic moisture sensitivity and interfacial instabi...
Sulfide-based solid electrolytes (SEs), including Li3PS4 (314), Li6PS5Cl (615), and Li7P3S11 (7311), offer high ionic conductivities suitable for all-solid-state batteries (ASSBs), yet suffer from intrinsic moisture sensitivity and interfacial instability with lithium metal. In this study, ZrCl4 doping is explored as a universal strategy to enhance the structural stability, ionic transport, and air tolerance of these three representative sulfide electrolytes. ZrCl4-doped samples are synthesized via high-energy ball milling, and their structural evolution, ionic conductivity, activation energy, and electrochemical performance are systematically evaluated. Across all systems, Zr–Cl co-doping produces chemically homogeneous and densely packed microstructures, as confirmed by SEM–EDS analyses, while maintaining the original crystalline framework. The 314, 615 and 7311 electrolytes show the most pronounced improvements, achieving maximum ionic conductivities of 1.12 mS·cm-1, 7.43 mS·cm-1 and 3.13 mS·cm-1, respectively. Activation energy measurements indicate reduced or marginally altered migration barriers depending on the host structure, reflecting distinct doping sensitivities among the sulfide systems. Air-exposure experiments reveal a substantial reduction in H2S generation-up to 60–70% lower than pristine samples—which is attributed to the formation of strong Zr–S bonds and Li–Cl-rich passivation layers. All-solid-state cells employing the doped electrolytes exhibit enhanced discharge capacity, improved coulombic efficiency, and superior cycling stability compared to undoped counterparts. These results demonstrate that ZrCl4 doping provides a robust and scalable approach for simultaneously improving ionic conduction, moisture resistance, and interfacial electrochemical stability in sulfide solid electrolytes. This work offers practical design guidelines for developing chemically durable and high-performance sulfide-based ASSBs.