Abstract
Microstructure, hardness, castability, and hydrogen evolution rate of cast SLI battery grids were determined for a wide range of Pb‐Ca and Pb‐Ca‐Sn alloy compositions. Calcium oxidation rate of the molten alloys was also studied. These properties were determined as a function of alloy composition, trace element content, and casting conditions. Grids were cast on a commercial calcium‐lead grid casting machine under production conditions. Grids were cast from two base leads: a low bismuth primary lead and a refined secondary lead containing bismuth, antimony, copper, and silver. Calcium was found to affect hardness and initial aging rate, while tin influenced grain size, castability, and calcium oxidation rate. Hydrogen evolution rate was also found to be a function of alloy composition. Trace element additions influenced hardness and hydrogen evolution in Pb‐Ca‐Sn alloys, and calcium oxidation rate and castability in Pb‐Ca alloys. Casting conditions influenced grain size and hardness at some alloy compositions.
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