Aluminum-air batteries are a promising next-generation technology due to their high energy density coupled with the abundance of aluminum and a well-established supply chain. One field that stands to particularly benefit from these greater capacities is aircraft electrification. Aviation applications pose a unique challenge in that the energy source for flight must provide a considerable upside relative to the weight it adds to the vehicle. Lithium-ion technology has been successfully implemented in drones for short flight times, but aluminum-air batteries have the potential to greatly extend the durations of these flights. While the energy density is where this chemistry has a unique competitive advantage, the power output presents a challenge. Although researchers have investigated lithium-ion battery discharge at high C-rates, most aluminum-air battery research has focused on maximizing utilization and energy density. For viable implementation in electric aircraft, focus must be placed on maximizing the power output of the aluminum-air chemistry with care to maintain the energy density that gives it its competitive advantage. At high power outputs, system performance is largely dictated by ohmic losses on the anode side associated with the aluminum product layer. Turnover of this secondary passivation layer is based on conversion of insoluble aluminum hydroxide to soluble aluminate ions, and this can be strongly influenced by several system parameters including electrolyte concentration, temperature, and flow rate. This investigation conducts a parametric analysis of these parameters with respect to their influence on resistance of the aluminum product film and its dissolution. The effects will primarily be studied using electrochemical impedance spectroscopy and polarization curves in conjunction with insight from Tafel analysis, surface imaging, and extended discharge testing. Both three-electrode and full-cell setups will be used for testing to allow for clear insight to surface-level processes and an idea of how the investigated factors scale up when implemented in a real system. Management of the aluminum product film is critical for achieving high power output, and this investigation will provide further insight to how key cell parameters influence the realization of this goal.
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