By combining alkaline etching of hydrogen storage alloys or their hydrides with a controlled oxidation, it was possible to improve reaction kinetics and accelerate activation of MH-electrodes. Both AB₅ and AB₂ alloys were studied where A is mixtures of rare earth elements for AB₅ alloys and titanium and/or vanadium, zirconium for AB₂ alloys; nickel contributes the major part of B. With SEM and TEM studies the surface could be described as consisting of several phases where an interphase with active Ni-containing cluster protected the inner metallic hydrogen storage part of the powder particles. These catalytic Ni-clusters presumably lead to the fast activation and high discharge capacity of alloy.

This interphase was observed to be stable enough to allow us to develop a method, where we could add pure oxygen to a NiMH battery pack in order to regenerate the amount of electrolyte that was lost during long time cycling of the battery. Meanwhile, the method will rebalance the electrodes mitigating excessive pressures during over charge. Therefore, the internal resistance of cells can be reduced and cycle life will increase.

It was also shown that the stable interphase could survive a mild ball milling or sonication which enabled us to upcycle material from spent NiMH batteries into a better working MH-electrodes with improved kinetics and activation properties. Reuse of ball-milled or sonicated material could serve as a simple recycling alternative to energy-demanding metallurgical smelting methods and chemical consuming hydrometallurgical recycling processes, where the possibilities of up-scaling further favour the less complex mechanical treatments. The stable but catalytic interphase protecting the inner particles indicates that the MH-electrode material may perform better in its second life in a new NiMH battery.

Nickel-Metal Hydride batteries (NiMH) have long cycle life. But in the end corrosion of the metal hydride is detrimental for life expectancy. Corrosion reduces the metal hydride capacity, but more severely it consumes water in the electrolyte resulting in increased internal resistance, which is the main cause for cell failure.

The corrosion, further, evolves hydrogen, causing an unbalance between anode and cathode, leading to premature internal pressure increase when the cells are approaching end of charge. This accelerates the drying out, if the cells vent through the safety valve.

In this study, a controlled addition of oxygen was used to rebalance the electrodes and replenish the electrolyte – as the added oxygen reacts with hydrogen that was formed during the corrosion process. Thus, the two most detrimental factors in cell ageing can be mitigated. To fully restore the electrolyte content as well as electrode balance, both oxygen and hydrogen are needed to compensate for the loss to hydroxide ions OH⁻ formed in the corrosion process. A proper optimization of the gas additions combined with a cell design including an excess amount of MH-alloy to compensate for the corrosion can substantially increase the cycle life of NiMH batteries.

Activation behavior of an AB(2), namely (Ti0.36Zr0.64) (V0.15Ni0.58Mn0.20Cr0.07)(2) Laves phase alloy, was investigated with regards to; particle size, ball milling and hot alkaline treatments. Galvanostatic cycling in open cells showed that an untreated alloy initially had almost no capacity, but reached a value of 220 mAh/g after 14 cycles. Experiments with different particle sizes showed that coarse particles activate faster yielding an improved capacity. In terms of activation more pronounced effect was obtained with boiling the alloy powder in a hot KOH solution. A capacity in excess of 300 mAh/g is reached in the first cycle after a 20 min treatment. The capacity was highest after 80 min, yielding a value of 390 mAh/g well above that expected from the gas-phase storage in the alloy. This was attributed to the formation of rough surface in the powder, which may stabilize hydrogen bubbles allowing pressures above 1 atm to be reached locally in the surface.

A surface treatment method has been developed to activate the surface of an AB(5) type (La-20 Ce-7 Pr-1 Nd-4 Al-2 Mn-5 Co-6 Ni-55) alloy. In the process the surface is covered with a porous surface layer containing needle shaped rare earth hydroxides after etching by a potassium hydroxide solution. TEM studies show in addition the presence of a denser surface oxide layer with embedded Ni containing clusters covering the bulk alloy. The magnetic properties of the alloy powders change with the surface treatment. In addition to a paramagnetic component of the bulk alloy, surface treated alloy also displays superparamagnetic and ferromagnetic properties. In electrochemical half-cell tests, the alloy shows better high-rate dischargeability with increasing presence of magnetic clusters in the metal hydride particles surface.

Oriented assembly of small crystals to form larger structures are common in nature and full understanding and control of such process would be beneficial for the forthcoming nano-technologies. Such bottom-up assembly of nano-structures most often requires a precursor of nano-sized crystals. Here we demonstrate a novel laser sintering process that can rupture a submicron-sized zirconia precursor into nano-sized crystals, followed by a rapid oriented assembly of these small crystals. A detailed structure study has been carried out to understand the complex process and a model has been proposed. Such a process sheds light on a new way of fabricating nano-materials using commercialized oxide materials.