Effect of porosity on discharge performance and corrosion resistance of 1060 aluminum alloy

This study investigates the effects of different porosities (0%, 11%, 19.6%, 28.3%) on the discharge behavior and corrosion resistance of 1060 Al alloy anodes in a 4 M NaOH electrolyte. Results indicate that the medium-porosity sample (MP, 19.6%) exhibits optimal comprehensive performance: a high polarization resistance of 22253 Ω·cm2, a corrosion current density of 2.793×10-3 mA·cm-2, the most stable discharge plateau and minimal voltage decay across a broad current density range of 2–40 mA·cm-2, along with uniform corrosion morphology. This study demonstrates that a 19.6% porosity achieves an optimal balance between effective expansion of the reaction interface and uniformity of current distribution, providing experimental evidence for the structural design of low-cost Al-air battery anodes.