Research, development and demonstration of nickel-iron batteries for electric-vehicle propulsion

The development of nickel-iron batteries was addressed to demonstrate improved performance features in electric vehicle battery systems. Performance improvements reported include: 30% increase in gravimetric energy density to 57 Wh/kg, 70% increase in volumetric enegy density to 116 Wh/1, and 5% increase in power density to 105 W/kg. In addition, a preliminary design was established for a multicell modular package that can further enhance these performance parameters by providing weight and volume reductions. Additional accomplishments are reported in process development by operating pilot line facilities to demonstrate the potential for $80/kWh OEM selling price. The potential for meeting the cycle life goal was enhanced by demonstration of: iron electrode life of over 1000 cycles at 80% depth of discharge (DOD), nickel electrode life of over 1000 cycles at 80% DOD, cell life of over 1000 cycles at 80% DOD, and 5-cell module life of 903 cycles at 80% DOD.