Hybrid Composite Foams Based on Pb Alloys for Lightweight Batteries

Abstract

A low-cost direct melt foaming approach was used to develop a new Pb alloy-based composite foam comprising hybrid of gas pores and closed cell porosity in the form of hollow ceramic particles to be an alternative to the traditional Pb grids in Lead acid battery (LAB). The novel Pb alloy-based composite foams were used as plates to manufacture lightweight LAB. The LAB was evaluated regarding weight saved and electrochemical performance, including cyclic voltammetry, galvanostatic polarization, and specific discharge capacity. The cyclic voltammetry results of the composite foams revealed that the composite foam required a higher voltage for oxidation, indicating that Pb oxidation occurred slower in the composite foams. Galvanostatic measurements showed that the composite foam took a long time to oxidize Pb into PbSO 4 , implying that the battery developed in the current work would have a longer lifespan than a conventional LAB. The LAB made of composite foams had a greater specific electrical discharge capability than a conventional LAB. The density of the composite foam was significantly smaller than the traditional lead alloy, showing that the weight of the composite foam plate was low. These findings suggested that the LAB with plates made of composite foams developed in the current study can be a feasible alternative to traditional Pb grids used in LAB.