Method of making anodes for hydrazine fuel cells

Claim 1

A method of making a fuel electrode for use in a hydrazine-fueled fuel cell including the steps of: a. making an electrically conductive support the cathode in a nickel electroplating cell; b. filling the cell with a nickel plating bath containing particles of carbonyl nickel; c. suspending the particles in the bath above the support by rapidly stirring the bath for a predetermined time; d. passing at least about 5 coulombs per square centimeter of support and less than 24 coulombs per square centimeter of support through said cell and over a time span which greatly exceeds said predetermined time to electrolyze said bath and plate electrolytic nickel onto the support; e. codepositing the particles onto the support along with the electrolytic nickel during said predetermined time; f. discontinuing said stirring after said predetermined time and allowing said particles to gravitate onto the support while continuing the nickel plating over said time span to electrolytically deposit sufficient electrolytic nickel onto the support to securely tack the particles to the support without appreciably degrading the characteristic rough and jagged surface of the nickel particles; g. contacting the support and wetting the nickel-bound particles thereon with a solution of a soluble nickel salt and solvent therefor; and h. contacting said wetted nickel-bound particles with a solution of an alkali metal borohydride and solvent therefor to form nickel boride in situ on the nickel-bound carbonyl nickel particles.