US20020148539A1 - Aluminum anodes and method of manufacture thereof - Google Patents

Aluminum anodes and method of manufacture thereof Download PDF

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Publication number
US20020148539A1
US20020148539A1 US10/075,340 US7534002A US2002148539A1 US 20020148539 A1 US20020148539 A1 US 20020148539A1 US 7534002 A US7534002 A US 7534002A US 2002148539 A1 US2002148539 A1 US 2002148539A1
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Prior art keywords
alloy
additive metal
aluminum
anode
matrix
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Abandoned
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US10/075,340
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English (en)
Inventor
Alexander Iarochenko
Evgeny Kulakov
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ALUMINUM-POWER Inc
Aluminum Power Inc
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Aluminum Power Inc
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Assigned to ALUMINUM-POWER, INC. reassignment ALUMINUM-POWER, INC. ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: IAROCHENKO, ALEXANDER M., KULAKOV, EVGENY B.
Publication of US20020148539A1 publication Critical patent/US20020148539A1/en
Assigned to ALUMINUM-POWER INC. reassignment ALUMINUM-POWER INC. ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: KARONIK, VALERI V.
Abandoned legal-status Critical Current

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    • CCHEMISTRY; METALLURGY
    • C22METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22CALLOYS
    • C22C1/00Making non-ferrous alloys
    • C22C1/02Making non-ferrous alloys by melting
    • C22C1/026Alloys based on aluminium
    • CCHEMISTRY; METALLURGY
    • C22METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22CALLOYS
    • C22C21/00Alloys based on aluminium
    • CCHEMISTRY; METALLURGY
    • C22METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22FCHANGING THE PHYSICAL STRUCTURE OF NON-FERROUS METALS AND NON-FERROUS ALLOYS
    • C22F1/00Changing the physical structure of non-ferrous metals or alloys by heat treatment or by hot or cold working
    • C22F1/04Changing the physical structure of non-ferrous metals or alloys by heat treatment or by hot or cold working of aluminium or alloys based thereon
    • HELECTRICITY
    • H01ELECTRIC ELEMENTS
    • H01MPROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M4/00Electrodes
    • H01M4/02Electrodes composed of, or comprising, active material
    • H01M4/36Selection of substances as active materials, active masses, active liquids
    • H01M4/38Selection of substances as active materials, active masses, active liquids of elements or alloys
    • H01M4/46Alloys based on magnesium or aluminium
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02EREDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
    • Y02E60/00Enabling technologies; Technologies with a potential or indirect contribution to GHG emissions mitigation
    • Y02E60/10Energy storage using batteries

Definitions

  • This invention relates to improved aluminum alloy anodes, to batteries and fuel cells comprising said anodes and to methods of manufacture of said anodes.
  • Aluminum anode/metal-air cathode batteries and fuel cells require a combination of competing electrochemical properties to be of practical and, particularly, commercial value.
  • the anode must be sufficiently highly active to provide high voltage and current, while on the other hand, the anode should not be active, i.e. corrode, when there is no power load requirement.
  • the anode should also uniformly react at its surface without pitting or selective dissolution.
  • Metals such as aluminum, zinc and magnesium in pure and technical grade form, i.e. greater than 99.5% purity do not provide a favourable balance of aforesaid electrochemical properties and, thus, are alloyed in admixture with suitable, but small amounts of additive metals to enhance electrochemical performance.
  • U.S. Pat. No. 4,792,430 discloses that addition of 0.03-0.2% tin to aluminum is beneficial in which the benefit can be further enhanced by the addition of 0.03-0.07% gallium and/or 0.002 to 0.006% silicon.
  • These beneficial alloys are produced by preparing a homogeneous mixture of the elements above their melting points and then subsequently cooling the mixture to produce a solid phase having the desired elements at their appropriate concentration.
  • U.S. Pat. No. 5,009,844 discloses the processing of aluminum alloy with a hypoeutectic composition by heating at a finite ( ⁇ 20° C./min) rate such that partial dissolution of the second phase occurs. A more uniform and spherical second phase residue is left after treatment.
  • a process of converting an alloy with a dendritic second phase into a uniformly dispersed second phase in a cast product is described in U.S. Pat. No. 5,911,843. The process uses thermal treatment which does not melt the alloy but allows the dendritic second phase to become dispersed.
  • the present invention provides that by a new physical process of homogeneous alloy melt formation with quenching at a rapid rate, followed by hot and/or cold rolling, improved electrochemical properties are achieved from alloys that would otherwise be considered to have low or no electrochemical property value.
  • the improvement in electrochemical behavior is postulated to be the result of a two phase structure of inclusions and matrix developed by the new physical processing, which phase structure can be observed by optical and electron microscopy.
  • the preferred physical structure seen in the present invention is not the uniform, small inclusion size favoured for producing good physical strength characteristics noted in the prior art but that having two types of inclusions, viz, larger dendritic inclusions comprising the majority of the metal additive and a finely dispersed inclusion making up the remainder of the metal additive.
  • a small amount of the metal additive ends up dissolved in the aluminum matrix.
  • Characterization of the structures of conventional prior art alloys and processed alloy of the same composition according to the invention shows that there is substantial physical difference in the materials. The preferred performance is obtained when the alloy, according to the invention, has been processed to provide >80% of the metal additive inclusions in elongated dendritic form and the remainder of the inclusions as dispersed relatively very tiny particles.
  • the invention provides a process of making an aluminum alloy anodic material having improved electrochemical properties for use in an electrochemical cell, said alloy consisting essentially of 95-99.5% w/w Al and 0.5-5.0 cumulative w/w additive metal selected from Group II-Group V metals of the Periodic Table, said process compromising heating 95-99.5% w/w Al and 0.5-5.0 cumulative % w/w addictive metal in admixture to a temperature to form a homogeneous matrix of melted alloy; cooling said melted alloy at a liquidus/solidus cooling rate to produce a solid, non-equilibrium alloy of a non-homogenous multiphase matrix comprising discrete relatively large crystals of pure aluminum and relatively smaller crystals of said additive metal included at the interface with said aluminum crystals; rolling said solid alloy to reduce its thickness to a factor of 0.2 to 0.01 to produce a rolled sheet of said alloy having a microstructure comprising an aluminum matrix having elongate inclusions of said additive metal and small
  • the additive metal is selected from Ga, In, Tl, Cd, Sn, Pb, Mn, Fe, and Mg; and more preferably, Mn, In, Sn and Fe.
  • a non-equilibrium multi-phase structure having large pure Al crystals of all shapes as one phase up to 5 cm long is produced and wherein the additive metal(s) are occluded at the Al periphery as one or more phases if one of more additive metals are present.
  • the aluminum crystals or grains in the pre-rolled alloy thus, preferably, have an average length selected from about 1-5 cm.
  • liquidus/solidus cooling rate in this specification means the cooling rate of about 10kg of a 3cm thick alloy matrix in a rectangular mould when cooled over the liquidus/solidus stage, i.e. from the temperature at which solidification of the melted alloy commences to the temperature at which it has completely solidified.
  • This solidification temperature range is, for example, typically, about 20-30° C. for alloy compositions of use in the practice of the invention, which commence to solidify at about 660° C. and are essentially solid at about 640° C.
  • a preferred cooling rate is selected from about 1° to 10° C. per minute, and more preferably selected from 2° to 5° C. per minute.
  • the alloy cooling step in the practice of the present invention may be suitably and readily achieved, preferably, for example by air cooling.
  • the melted admixture is cooled at such a rate as to produce a non-equilibrium, solid alloy, multi-phase matrix, as hereinabove defined. If the melt is cooled too quickly, a homogeneous multi-metallic phase having no or little discrete crystals is obtained. If the cooling rate is too slow, multi-phases of the different metals, each as relatively large inclusions, non-uniformly distributed throughout the thickness of the mass is undesirably obtained.
  • the melted alloy may be readily melted and transferred to a typical mould for cooling at the aforesaid desired rate.
  • An essentially rectangularly shaped, mould of internal dimensions selected, for example, from 3-5 cm, wide, 5-20 cm long and 10-50 cm high to accommodate 1-10 Kg alloy may be used.
  • microstructures may be viewed by optical and electron microscopy.
  • the rolling step of use in the practice of the invention may comprise either hot rolling or cold rolling techniques or, preferably, conventional hot rolling at a temperature selected from 200-560° C., followed by cold rolling. Reductions by hot rolling to 10-20% of the original thickness, followed by further reductions to 2-10% of the original thickness by cold rolling is most preferred.
  • the resulting thickness of the rolled plate, sheet, film, foil and the like of the order of 0.2-2 mm, preferably, about 0.5 mm is of particular value as an anodic material in the practice of one aspect of the invention, in batteries, and have been found to provide enhanced current density activity.
  • the cold rolling step causes the aluminum crystals to merge under the shearing action to form a bulk matrix, and the relatively large additive metal occlusions to elongate as occlusions within the aluminum matrix, which occlusions are surrounded by a plurality of much smaller, fragmented satellite additive metal occlusions dispersed in the matrix.
  • the rolling steps are beneficially enhanced by use of lubricating oils.
  • FIGS. 1 A- 1 D represent electron microscopic images of an aluminum/indium cast alloy according to the invention
  • FIGS. 2 A- 2 D represent electron microscopic images in cross-section perpendicular to the direction of rolling of the alloy of Example 1 after rolling as described therein;
  • FIG. 3 represents a sketch of a test cell used to determine anode potentials and corrosion rates of anode alloys according to the invention
  • FIG. 4 represents graphs of the polarization characteristics Pa (anode) as a function of current density of test anodes of 99.4% w/w (Al 99.95% pure)+0.6% In, manufactured by different methods;
  • FIG. 5 represents graphs of the discharge characteristics Pa (anode) of the anode materials manufactured as described with reference to FIG. 4;
  • FIG. 6 represents curves showing the dependency of the corrosion current density I(corr.) on the relative amount of additive in anode materials manufactured as described with reference to FIG. 4;
  • FIG. 7 shows comparative graphs of the polarization characteristics Pa(anode) in volts as a function of current density of several test anodes with various additive metals manufactured by different methods
  • FIG. 8 represents graphs of the discharge characteristics Pa(anode) volts of various anode alloy materials as described with reference to FIG. 7;
  • FIG. 9 represents graphs showing comparative corrosion current densities against anode current densities for the alloys described with reference to FIGS. 7 and 8, manufactured according to the invention.
  • Al (9.5Kg. 99.95% purity) and In (0.5Kg.) were melted in admixture to just above its melting point at about 660° C. and forced air-cooled in a carbon-lined, rectangularly-shaped chamber having a width of 3 cm, over a period of 30 minutes, and a crystallization liquidus/solidus temperature range of about 20° C. to achieve the aforesaid non-equilibrium, homogeneous, crystal-forming conditions distinct from non-heterogeneous amorphous solidification.
  • the resultant alloy plate was hot-rolled at 500° C. to a thickness of about 3 mm and cold rolled to a thickness of about 0.5 mm.
  • Example 1 was repeated wherein a 10cm thick amount of the melted alloy of Example 1 was air-cooled over a period of 10 hours.
  • Example 1 process conditions were repeated with a 99.7% aluminum/0.3% indium alloy.
  • FIG. 1 shows electron microscopic structures of the aluminum/indium alloy cast according to Example 1 prior to hot/cold rolling.
  • FIGS. 1A and 1B, enlarged ⁇ 200 and ⁇ 400, respectively, show large aluminum crystals of 1.5 cm length having indium colonies on the periphery of the aluminum grains.
  • FIG. 1C at an enlargement of ⁇ 4000 shows indium colonies as spherical bodies of approximately 1.6 micron diameter or elongated occlusions of approximately 10 microns in length.
  • FIG. 1D shows the internal structure of the indium colony at a magnification of ⁇ 10,000.
  • FIG. 2 shows the rolled alloy wherein FIGS. 2A and 2C represent a strip, foil and the like of thickness 1 mm at a magnification of ⁇ 2600 and ⁇ 6000, respectively, while FIGS. 2B and 2D are 3 mm thick and at a magnification of ⁇ 2000 and ⁇ 6000, respectively. Satellite indium inclusions of not larger than 0.1-0.2 micron diameter can be seen to be interspersed among the larger elongate indium crystals.
  • FIG. 3 shows generally as 10 the test cell used to determine anode potentials and rates of corrosion of the aluminum alloys under test.
  • Cell 10 has a cylindrical body 12 hermetically sealed between removable end covers 14 against gaskets 16 .
  • Body 12 at an upper part has a side tube 18 for release of hydrogen under test.
  • Coaxial within body 12 is a reference electrode 20 adjacent disc 22 of specimen anode under test.
  • Terminals 24 , 26 are located at upper and lower covers 14 , respectively for contact with electrode 20 and disc 22 , respectively, for measuring Pr (reference) and Pa (anode), respectively.
  • Cell 10 contains aqueous potassium hydroxide (4 mol/L) electrolyte with 0.6% w/w potassium stannate additive, 28 . The temperature was controlled to that specified by the testing requirements.
  • this shows the polarization characteristics Pa (anode) as a function of current density of test anode alloys comprising 99.4% Al and 0.6% In, wherein the alloy is made as follows.
  • Curve 1 is for the aforesaid alloy made according to the present invention, comprising the general steps of
  • Curve 2 is as far as step a., only.
  • Curve 3 is cast and hot and cold rolled according to conventional prior art manufacturing methods.
  • the efficiency of the anode electrode manufactured according to the invention is superior for nominal and large current loadings of the anode as compared to the regular anode alloys made using the method according to the prior art.
  • FIG. 5 shows the discharge characteristics against time for the three anode materials manufactured as described with reference to FIG. 4, in the same electrolyte composition and at the same temperature of 60° C., and a discharge current density of 100 ma/cm 2 , using the cell described in FIG. 3.
  • FIG. 6 shows corrosion current density I(corr.) curves for materials made by each of the three methods of manufacture described with reference to FIG. 4, using the test cell described in FIG. 3 under the same conditions of temperature in the same electrolyte.
  • curves of FIG. 6 show that the anode alloy according to the invention (curve 1 ) provides the most advantageous values of corrosion current density from 10 to 20 ma/cm 2 within the range of from 0.05 to 1.4% w/w of the additive In.
  • the maximum value of the corrosion current density of about 20 ma/cm 2 falls within the range of 0.5-0.8% w/w In.
  • this shows a series of curves obtained under the same conditions and manner as described with reference to FIG. 4, representing the polarization characteristics as a function of current density of test anode alloys comprising as follows:
  • Mn 99.97%Al+0.03%/oMn
  • Fe 99.99%Al+0.01% Fe; and wherein in each trio of curves:
  • Lines 1 denote the respective aforesaid alloy made according to the invention.
  • Line 2 denote the respective aforesaid alloy made according to the pre-rolled invention process step only;
  • Lines 3 denote the respective aforesaid alloy made according to a conventional prior art cast and hot and cold rolled manufacturing method.
  • FIG. 8 shows discharge characteristics against time for the four different metal compositions, of anode materials manufactured as described with reference to FIG. 7 in the same electrolyte composition, at the same temperature of 60° C., and a discharge current density of 100 ma/cm 2 using the cell described in FIG. 3.
  • FIG. 9 shows comparative graphs of different alloys made according to the method of manufacture according to the invention, as follows:
  • the anode material according to the invention as described under Example 1 was subjected to subsequent additional thermal treatment of different temperatures and time periods.
  • the additional treatment steps included, for example, tempering, annealing, and cooling as given in Table 1.
  • Table 1 Also given in Table 1 are the electrochemical values obtained from the test cell described with reference to FIG. 3 operated at 60° C. Values of the anode potentials, corrosion rates and effective activation energy—which is related to the corrosion current and temperature by the Arrhenius Equation.
  • the processing set forth clearly demonstrates a method to produce an anode material that has superior electrochemical properties; initially (high initial voltage see Table 1); during discharge (high voltage during discharge at high currents, see FIG. 4); and at end of discharge by way of greater capacity (smaller corrosion rates see FIG. 5).
  • anode alloys according to the invention have about one order lower corrosion current density relative to the alloy of the same composition made according to the prior art, while having more efficient volt-ampere characteristics when used at medium and particularly high anode current densities; and also has a relatively larger energy capacity to provide superior discharge characteristics.

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  • Chemical & Material Sciences (AREA)
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  • Materials Engineering (AREA)
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US10/075,340 2001-03-02 2002-02-15 Aluminum anodes and method of manufacture thereof Abandoned US20020148539A1 (en)

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CA002339059A CA2339059A1 (fr) 2001-03-02 2001-03-02 Anodes en aluminium et methode de fabrication connexe

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Cited By (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US20100310937A1 (en) * 2009-06-09 2010-12-09 3M Innovative Properties Company Thin film alloy electrodes
US9912008B2 (en) 2013-11-12 2018-03-06 Intec Energy Storage Corporation Electrical energy storage device with non-aqueous electrolyte
CN111041391A (zh) * 2019-12-04 2020-04-21 中车青岛四方机车车辆股份有限公司 一种铝合金挤压型材及其在线淬火工艺
CN113957305A (zh) * 2021-10-25 2022-01-21 重庆国创轻合金研究院有限公司 一种新能源电池动力用含Sc的高活性铝合金阳极材料及其制备方法

Families Citing this family (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2005069411A1 (fr) 2004-01-13 2005-07-28 Avestor Limited Partnership Procede et appareil permettant de fabriquer des films d'electrode positive pour des batteries polymeres
WO2018109767A1 (fr) 2016-12-15 2018-06-21 Phinergy Ltd. Système et procédé pour initialiser et faire fonctionner une pile métal-air

Citations (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4288500A (en) * 1979-08-28 1981-09-08 Institute Of Technical Sciences Of The Serbian Academy Of Sciences And Art Electrochemically active aluminum alloy and composite
US4996129A (en) * 1988-01-05 1991-02-26 Alcan International Limited Battery
US5925313A (en) * 1995-05-01 1999-07-20 Kabushiki Kaisha Kobe Seiko Sho Aluminum base alloy containing boron and manufacturing method thereof

Family Cites Families (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4554131A (en) * 1984-09-28 1985-11-19 The United States Of America As Represented By The Department Of Energy Aluminum battery alloys
NZ224999A (en) * 1987-06-16 1990-10-26 Comalco Alu Aluminium alloy suitable for sacrificial anodes

Patent Citations (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4288500A (en) * 1979-08-28 1981-09-08 Institute Of Technical Sciences Of The Serbian Academy Of Sciences And Art Electrochemically active aluminum alloy and composite
US4996129A (en) * 1988-01-05 1991-02-26 Alcan International Limited Battery
US5925313A (en) * 1995-05-01 1999-07-20 Kabushiki Kaisha Kobe Seiko Sho Aluminum base alloy containing boron and manufacturing method thereof

Cited By (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US20100310937A1 (en) * 2009-06-09 2010-12-09 3M Innovative Properties Company Thin film alloy electrodes
CN102804457A (zh) * 2009-06-09 2012-11-28 3M创新有限公司 薄膜合金电极
US8420261B2 (en) 2009-06-09 2013-04-16 3M Innovative Properties Company Thin film alloy electrodes
US9912008B2 (en) 2013-11-12 2018-03-06 Intec Energy Storage Corporation Electrical energy storage device with non-aqueous electrolyte
CN111041391A (zh) * 2019-12-04 2020-04-21 中车青岛四方机车车辆股份有限公司 一种铝合金挤压型材及其在线淬火工艺
CN113957305A (zh) * 2021-10-25 2022-01-21 重庆国创轻合金研究院有限公司 一种新能源电池动力用含Sc的高活性铝合金阳极材料及其制备方法

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WO2002071513A3 (fr) 2004-01-29
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