Aluminum-MnO2 (Al/MnO2) dry cells of "D" size configuration are investigated as an alternative to the Lechlanche dry cell, where aluminum is replaced for zinc as the anode, MnO2 as the cathode, and a mixture of aluminum chloride/ammonium chloride/chromium chloride as the electrolyte. Investigations regarding the optimization of conducting material, electrolyte composition, and electrochemical performance of the cell at different temperature and current drains (100, 200, and 400 mA) are carried out. Internal resistance and storage life of the fabricated aluminum dry cells are also evaluated. The results suggest that Al/MnO2 dry cells exhibit a superior performance than their Zn counterpart. (C) 2008 The Electrochemical Society.