Fe-air or Ni-Fe cells can offer low-cost and large-scale sustainable energy storage. At present, they are limited by low coulombic efficiency, low active material use, and poor rate capability. To overcome these challenges, two types of nanostructured doped iron materials were investigated: (1) copper and tin doped iron (CuSn); and (2) tin doped iron (Sn). Single-wall carbon nanotube (SWCNT) was added to the electrode and LiOH to the electrolyte. In the 2 wt. % Cu + 2 wt. % Sn sample, the addition of SWCNT increased the discharge capacity from 430 to 475 mAh g−1, and charge efficiency increased from 83% to 93.5%. With the addition of both SWCNT and LiOH, the charge efficiency and discharge capacity improved to 91% and 603 mAh g−1, respectively. Meanwhile, the 4 wt. % Sn substituted sample performance is not on par with the 2 wt. % Cu + 2 wt. % Sn sample. The dopant elements (Cu and Sn) and additives (SWCNT and LiOH) have a major impact on the electrode performance. To understand the relation between hydrogen evolution and charge current density, we have used in operando charging measurements combined with mass spectrometry to quantify the evolved hydrogen. The electrodes that were subjected to prolonged overcharge upon hydrogen evolution failed rapidly. This insight could help in the development of better charging schemes for the iron electrodes.
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