General Competition (October 1997)

Advanced Magnesium Alloys Production Process (AMAPP)

Sponsor: Energy Conversion Devices (formerly Ovonic Battery Company)

• Project Performance Period: 10/1/1997 - 4/30/2001
• Total project (est.): $18,904,388.00
• Requested ATP funds: $8,206,088.00

Nickel-metal-hydride (NiMH) batteries are used in many portable electric and electronic devices and have captured more than 30 percent of the market for rechargeable batteries. Among their advantages, current NiMH batteries store two times more energy and are environmentally superior to lead-acid and nickel-cadmium batteries. Using proprietary approaches, Ovonic Battery, original developer of NiMH technology and a subsidiary of Energy Conversion Devices (Troy, MI), and Manufacturing Sciences Corporation (Denver, CO) propose to develop advanced materials technology for future low-cost, high-energy-density improved NiMH batteries using magnesium-based hydrogen storage materials for the negative electrode. The materials used in current NiMH battery production are rare-earth metals and zirconium alloys, which are more expensive than magnesium. Magnesium is lightweight, low cost, and has superior hydrogen storage capacity, but until now its use in batteries has been prevented by slow hydrogen absorption and desorption at ambient temperatures and the ready oxidation of magnesium alloys. The companies propose to overcome these challenges by developing new thin-film magnesium alloys using a novel rapid solidification process, which will yield materials with special microstructures, and tailored alloy surface properties. In addition to their own capabilities, the companies will use processing facilities at Oak Ridge National Laboratory, the Colorado School of Mines, and Iowa State University. Improved NiMH batteries will help build a U.S. industry base in the rapidly growing rechargeable battery market. Such batteries also will enable the widespread use of sustainable energy systems, such as practical electric vehicles and stand-alone photovoltaic power systems. In addition, a new U.S. industry could be built around the magnesium alloy materials, which also could be used to store hydrogen for use in fuel cells and solid-state heat pumps.

For project information:

Subhash Dhar, (248) 362-1750
skdobc@earthlink.net

Active Project Participants

• Crucible Materials Corporation (CMC), Crucible Research Center (Pittsburgh, PA)
  [New Member since original JV was formed]
  

ATP Project Manager

Eric Samuelson, (301) 975-6393
eric.samuelson@nist.gov