Optimization of Mechanical and Process Parameters for Enhanced Energy Conversion Efficiency in the Aluminum-Air Batteries

In this study, we focused on enhancing the performance of aluminum-air batteries by optimizing the cathode's material composition and manufacturing parameters. The catalyst layer, consisting of amorphous manganese dioxide (MnO₂), graphite, and carbon black, was systematically improved to maximize oxygen reduction reaction (ORR) efficiency. Additionally, the gas diffusion layer (GDL), composed of activated carbon and polytetrafluoroethylene (PTFE), was refined to ensure optimal gas permeability and mechanical stability. Through galvanostatic discharge tests, the optimized battery demonstrated a stable voltage of 1.8 V at a current density of 20 mA/cm², with significant improvements in energy efficiency and discharge stability. The final optimized cathode composition included 60% MnO₂, 30% graphite, and 10% carbon black, sintered at 310°C. This combination resulted in a uniform PTFE distribution and enhanced three-phase reaction sites, critical for efficient ORR kinetics. These findings highlight the potential of cost-effective, readily available materials for achieving high-performance aluminum-air batteries, paving the way for sustainable and economically viable energy storage solutions.