Variables affecting the deep-cycling characteristics of expanded-grid lead/acid battery plates

Abstract A large number of experimental lead/acid cells have been constructed, cycled, and examined using metallographic techniques in order to evaluate the influence of cell fabrication and operating variables on capacity retention. The effects of grid alloy (especially tin and calcium contents in expanded grids), extent of recharge, processing variables, additives and other parameters have been investigated and some of the results are presented here. Under the experimental conditions, long cycle-lives have been obtained, without any rapid or premature capacity loss for non-antimonial alloys, regardless of the presence or absence of tin in the grid alloy. The main influence of tin appeared to be related to the corrosion and growth characteristics of the grid. With 115% constant-current recharge, cell failures for certain grid alloys (e.g., low-calcium, high-tin lead alloys) were due to corrosion and wire breakage. For preferred alloys, and at 105% recharge, capacity losses were brought about by less obvious factors. The latter were apparently related to grid growth, active material degradation, and/or loss of electrical continuity with the current collector. Some evidence has been found for the formation of PbSO 4 and α-PbO in the corrosion layer; this may have contributed to performance degradation. Neither of these lead species, however, appeared to form a continuous barrier in recharged plates or to cause sudden capacity loss. The charging regime chosen was suitable to ensure good cycle-life regardless of tin content and some of the other variables studied. A different cycling regime and state-of-charge for plate removal and examination is required in order to study corrosion-layer passivation, which was largely absent in this work.

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