Li-alloy/FeS cell design and analysis report

This report contains historical information on the Li-alloy/FeS system that will be useful in its future applications. This document includes the following: (1) the chemical and electrochemical reactions for the Li-alloy/FeS system, accomplishments in past cell development efforts, and performance attained by state-of-the-art cells vs performance goals; (2) detailed drawings of state-of-the-art cell designs, documentation of cell fabrication techniques, and comparisons of alternative types of cell components (such as BN felt vs MgO powder separators, stainless vs low-carbon steel cell housings) and fabrication techniques (such as charged vs uncharged electrodes); (3) results of post-test cell analyses, including cell failure mechanisms, electrode morphology and active material distribution, and in-cell corrosion rates; (4) data from trade-off studies between specific power and energy; (5) discussion of battery design considerations (e.g., volumetric energy density, battery charger, and high-efficiency thermal insulation); (6) results of cost studies, which include materials and manufacturing costs of cells and batteries and heating costs involved in battery operation; and (7) projections of cell designs having the greatest potential for meeting electric-vehicle performance requirements.