Thin Film Thermal Battery Electrode Production by HVOF Thermal Spray of Nanostructured FeS(2) Feed

Li-Alloy/FeS2 thermal batteries are the predominant thermal cell chemistry today, and have been deployed in MICOM missiles (replacing Ag-Zn). Despite progress, the use of pressed powders for thermal batteries has several intrinsic limitations. A more efficient means of providing thinner catholyte electrodes would drastically increase the volumetric and gravimetric efficiency of thermal batteries. The objective of this proposal is to develop a process for the deposition of a thin coherent and adherent film of FeS(2) on a metal (e.g., Fe or SS) sub strate. The proposed research is intended to demonstrate the feasibility of exploiting the unique properties of an exciting new class of ructured al nanometers, where 1 nm = 10 angstroms) as the active ingredients for high performance thin cell thermal batteries. The principals of US Nanocorp, Inc. have developed techniques for the synthesis and processing of nanostructured materials and their use as feedstocks for thermal spray. The proposed program will examine the feasibility of fabricating thin cell electrodes for thermal batteries by the process of thermal spray of nanostructured FeS(2). HVOF thermal spray avoids the elevated temperatures of DC arc plasma techniques that would melt the feedstock. Sandia National Labs has agreed to participate in the program. BENEFITS: It is estimiated that the Military uses more than 3800 different types of batteries with an annual procurement cost exceeding $300 million. This innovative approach for the production of thin film electrodes can be applied to many other battery systems, including nickel alkaline and rechargeable lithium batteries. It can also be applied to fuel cells, e.g., in the deposition of thin films of YSZ in SOFCs.