In order to improve the electrochemical activity and discharge performance of aluminum–air batteries and to reduce self-corrosion of the anode, an SLM-manufactured aluminum alloy was employed as the anode of the Al-air battery, and the influence of PAAS and ZnO inhibitors taken separately or together on the self-corrosion rate and discharge performance of the Al-air battery in a 4 M NaOH solution were investigated. The experimental result indicated that the effect of a composite corrosion inhibitor was stronger than that of a single corrosion inhibitor. The addition of the compound inhibitor not only promoted the activation of the anode but also formed a more stable composite protective film on the surface of the anode, which effectively slowed down the self-corrosion and improved the utilization rate of the anode. In NaOH/PAAS/ZnO electrolytes, the dissolution of the Al6061 alloy was mainly controlled by the diffusion of the electric charge in the corrosion products or the zinc salt deposition layer. Meanwhile, for the Al-air battery, the discharge voltage, specific capacity, and specific energy increased by 21.74%, 26.72%, and 54.20%, respectively. In addition, the inhibition mechanism of the composite corrosion inhibitor was also expounded. The excellent discharge performance was due to the addition of the composite corrosion inhibitor, which promoted the charge transfer of the anode reaction, improved the anode’s activity, and promoted the uniform corrosion of the anode. This study provides ideas for the application of aluminum–air batteries in the field of new energy.

To improve the discharge performance of aluminum–air batteries, CeO₂/Al6061 composites were prepared as an anode using selective laser melting (SLM). Response surface methodology (RSM) was employed, and the test results were linearly fitted. A prediction model for the forming quality of the composite anode was established, and the reliability of the model and the interaction between process parameters were explored based on variance analysis and significance testing. On this basis, with corrosion potential, self-corrosion rate, and discharge voltage as optimization objectives, the optimal solution set of the SLM forming CeO₂/Al6061 anode process parameter was solved through a genetic algorithm, and experimental verification was conducted. The results indicate that the optimal process range for the forming quality and various properties of composite materials is laser power of 265~285 W, scanning speed of 985~1025 mm/s, and scanning spacing of 0.116~0.140 mm. The optimized process parameters were selected for reliability testing, and the errors were all within 3.0%, verifying the accuracy and reliability of the model.