Enhancing Electrochemical Performance of Lead-Acid Batteries Using Surface Modified Novel Al Grid as Electrode Substrate

In the present research, aluminum expanded mesh grids are considered for negative electrodes in lead-acid batteries. The conventional negative electrodes made from lead alloy grids are replaced by the expanded mesh grids that are made from a commercial aluminum alloy as they are lightweight, have higher conductivity, and are available in bulk. To accomplish this, aluminum grids were considered with their surfaces modified by lead coatings prior to electrode preparation. Hence Al grids find an envious place in lead-acid battery applications. In this study, Al grids were pretreated for surface cleaning followed by Zn coating, electroplating with Cu and hot-dip coating in a molten Pb alloy bath. The surface coated Al grids were analyzed using X-ray diffraction, field emission scanning electron microscopy, and energy dispersive X-ray analysis elemental mapping. Microhardness measurements were made on the prepared specimens. Electrochemical performance tests on 2V batteries at higher discharge rates and life cycles were conducted. The specific energy of batteries with Al grids was 80 W h/kg, which is 20% higher than that of a Pb grid type. By replacing Pb grids with surface modified Al grids in lead-acid batteries, the consumption of lead gets reduced by 5%, resulting in a cost-effective and environment-friendly approach.