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The consistency in capacity degradation in a multi-cell pack (>100 cells) is critical for ensuring long service life for propulsion applications. As the first step of optimizing a battery system design, academic publications regarding the capacity degradation mechanisms and possible solutions for cycled nickel/metal hydride (Ni/MH) rechargeable batteries under various usage conditions are reviewed. The commonly used analytic methods for determining the failure mode are also presented here. The most common failure mode of a Ni/MH battery is an increase in the cell impedance due to electrolyte dry-out that occurs from venting and active electrode material degradation/disintegration. This work provides a summary of effective methods to extend Ni/MH cell cycle life through negative electrode formula optimizations and binder selection, positive electrode additives and coatings, electrolyte optimization, cell design, and others. Methods of reviving and recycling used/spent batteries are also reviewed.

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