The abundance, environmental friendliness and high energy density of magnesium makes it an attractive option for eco-friendly battery development. This research article explores the performance of commercial magnesium alloys AZ31, AZ61 AZ91 in seawater battery applications, with a focus on corrosion resistance, discharge efficiency and long-term stability. The study highlights the role of aluminium concentration in these alloys, with a specific emphasis on how variations in concentration impact the performance metrics such as corrosion susceptibility, hydrogen evolution and anode utilization. Increasing the aluminium concentration to around 6 wt % in AZ61 not only boosts discharge activation but also enables the formation of protective magnesium aluminide (Mg17Al12), which acts as a barrier, preventing the self-peeling of corrosion products and enhancing stability during prolonged discharge. AZ61 emerges as the optimal alloy, balancing corrosion resistance, discharge efficiency, high anode utilization factor and long-term stability in highly corrosive seawater conditions. The results of electrochemical and discharge performance testing are supported by electrochemical impedance spectroscopy (EIS), scanning electron microscopy (SEM) and X-ray diffraction (XRD) analysis. The work offers a framework for future research that can boost the development on design of seawater battery with corrosion-resistant materials, high discharge efficiency and minimal adverse environmental impact.
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