Dehydration¶
There's a secondary degradation mechanism that's worth noting for those who have seemingly unrecoverable cells in a Prius: dehydration.
Looking again at the NiMH battery chemistry -
Anode: $\ce{H2O + M + e^- <=> OH^- + MH}$
Cathode: $\ce{Ni(OH)2 + OH^- <=> NiO(OH) + H2O + e^-}$
you can see that water - $\ce{H2O}$ - is involved but not consumed in the reactions. This is also kind of transparently obvious: you need an electrolyte for ion exchange. What is not obvious though is that the situation under battery charging is technically a competitive with a straight electrolytic water-splitting reaction:
$\ce{2H2O <=> 2H^2 + O^2}$
This is a known problem - though largely resolved from normal recombinative processes in the battery (having a shared gas headspace allows the H2 and O2 to recombine back into water) and can be assisted by adding specific recombination chemistry and normally just resembles a loss function on charging the cells, simply producing heat.
This is a tradeoff in battery design: a sealed cell doesn't leak gas, which ensures it can eventually recombine. But a sealed cell can overpressure and rupture, at which point the cell is destroyed. The Prius cells are not sealed - a one-way overpressure blow off valve is present which vents at 80-120 psi - 550-828 kPa (this is substantial) - and the cells themselves depend on being clamped to prevent gas pressure from damaging them during charging.
But the result is the same: failed seals or overheated cells over a long duration may have lost water through either electrolysis processes.
There are ways to fix this sort of failure - and the results are spectacular - but this is definitely into "last resort for experimentalists" sort of intervention. Typical NiMH design uses a 20-40% w/v KOH solution in water. LiOH is added to improve low temperature performance, and NaOH is substituted partially or fully for reduced corrosion in high temperature applications.
Per this link 30% w/v KOH and 1.5 g/L LiOH is suggested. For the purposes of cell rehydration, an exact match is probably not important as a "dried out cell" will still contain all its salt components (though depending on redissolving them may not be the best option). A starting point for other mixes might be this paper which concludes a 6M KOH solution is optimal.
The big results reported over by this PriusChat member for anyone considering this are here - where he notes he used 20% KOH. Of note: getting deionized water, and a suitably un-metal contaminated salt, is probably key to success here (as well as sealing up the cells properly - the trickiest part by all accounts). That said - various metal dopants are used in NiMH cells to contribute all sorts of properties, so this may be a small effect. It is worth worrying about polymeric impurities in salts - you can eliminate these by "roasting" the salt to turn the into carbon ash.
It is noted in the literature that 6-8M KOH is the sweet spot for discharge capacity - however the use of a 1M solution for total cycle life has also been noted here.
One key parameter for anyone considering this is a rule of thumb figure for electrolyte volume of 1.5 - 2.5 mL A/h. For Prius cells this corresponds to 9.75 - 16.25 mL per cell, or 58.5 - 97.5 mL per module (each module has 6 cells).