The discharge capacity of a porous iron electrode is controlled by either the extent of interparticle neck growth achieved during sintering or the amount of surface area retained following sintering. The mode of capacity control is related to the density of the electrode.Several key studies have been made of the chemical reactions which accompany the first step discharge of an iron electrode in KOH electrolyte (1, 2). It has also been established that the Fe(OH)2 product of the first piateau discharge is formed by a dissolutionprecipitation mechanism (2, 3). However, in terms of the physical structure of an iron electrode as it affects the discharge capacity on the first plateau, little has been written. Hancock and Strasser (4) have demonstrated that the use of various iron powders to increase electrode surface area provided a corresponding increase in discharge capacity.In the present work capacity is examined as a function of electrode density and the results compared to a porosity (density) model proposed by Selanger (5). Finally, the physical features of an iron electrode which determine its capacity are examined and discussed.Procedure Sponge iron powder was prepared by the hydrogen reduction of Fe208. Two lots of powder were used in the study. They were designated as lots A and B and had respective BET surface areas of 4.4 m2/g and 7.3 m2/g. Green electrodes having nominal dimensions of 0.31 cm (thick) by 3.2 cm by 3.2 cm and a nominal density of 17.2% TDFe (percent of the theoretical density of iron) were prepared by pressing powder between pairs of perforated nickel current collectors. Sintering in flowing hydrogen for various times at temperatures between 650 ~ and 900~ provided electrodes having densities ranging from 18.1 to 25.8% TDFe. A current collector tab was then spot welded to one face of each electrode.The electrodes were automatically tested at 44~ against nickel sheet electrodes in 25 weight percent (w/o) KOH containing 15 g/liter LiOH. Test conditions included a 100 mA/cm 2 charge current density and a 50 mA/cm 2 discharge current density to a cutoff voltage of 0.750V (vs. a Hg/HgO reference electrode). A large excess of electrolyte, relative to the weight of iron, was employed to minimize the need for water makeup to the electrolyte. Discharge capacities for electrodes prepared from each powder were determined.Experimental Results Because of its relative ease of measurement, the density of a pressed and sintered body has often been adopted as a measure of its physical structure. To test the usefulness of this measure to correlate the capacity data of the present work, the capacities of electrodes prepared by numerous combinations of sintering time and temperature were determined as a function of electrode density. These results, for lot A and lot B electrodes respectively, are given in Fig. 1 and 2.According to the porosity model proposed by Selanger, a maximum achievable discharge capacity * Electrocl~emical Society Active Member.