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<p>Alloying alkaline metals (AMs) and/or alkaline-earth metals (AEMs) with lead (Pb) is an effective way to increase the mechanical strength of Pb alloys that are commonly employed as grids of lead-acid batteries (LABs). However, current methods for making AM/AEM-Pb alloys by physically mixing pure AM/AEM and Pb face challenges such as instantaneous thermal runaway from exothermic alloy reactions and oxidation of AM/AEM. Herein, sodium-lead (Na–Pb) alloy is directly prepared by molten salt electrolysis without generating Cl<sub>2</sub> gas using a molten NaCl–Na<sub>2</sub>CO<sub>3</sub> electrolyte with a current efficiency of above 80&#xa0;pct at 200 mA·cm<sup>-2</sup>, because the discharge of CO<sub>3</sub><sup>2−</sup> is significantly more favorable than that of Cl<sup>−</sup> at the graphite anode. Furthermore, the reduction of Na<sup>+</sup> on the liquid Pb electrode happens at a potential more positive than the reduction of pure Na. The diffusion coefficient of Na in liquid Pb is measured as 3.22&#xa0;×&#xa0;10<sup>−4</sup>&#xa0;cm<sup>2</sup>&#xa0;s<sup>−1</sup> at 750&#xa0;°C by the galvanostatic intermittent titration technique (GITT), and the simulated electrolysis current density is 200&#xa0;mA&#xa0;cm<sup>−2</sup>. Moreover, the prepared Pb–Ca–Na–Al using the electrolytic Na-Pb alloys achieves a significant mechanical strength improvement (27&#xa0;pct increase of the hardness, 60&#xa0;pct increase of the creep resistance). Overall, molten salt electrolysis offers a clean and efficient method for preparing various Pb alloys for next-generation LABs and other applications.</p>

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An Electrochemical Approach to Prepare Liquid Sodium-Lead Alloy using a Molten NaCl–Na2CO3 Electrolyte

  • 期刊论文

  • 发表日期：

    2025年6月4日

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  • Yongxin Wu,
  • Hongya Wang,
  • Mengli Xiang,
  • Zuojun Hu,
  • Hao Shi,
  • Fangzhao Pang,
  • Bingbing Wang,
  • Xiong Zhang,
  • Dihua Wang,
  • Xiaowei Liu,
  • Huayi Yin

摘要

Alloying alkaline metals (AMs) and/or alkaline-earth metals (AEMs) with lead (Pb) is an effective way to increase the mechanical strength of Pb alloys that are commonly employed as grids of lead-acid batteries (LABs). However, current methods for making AM/AEM-Pb alloys by physically mixing pure AM/AEM and Pb face challenges such as instantaneous thermal runaway from exothermic alloy reactions and oxidation of AM/AEM. Herein, sodium-lead (Na–Pb) alloy is directly prepared by molten salt electrolysis without generating Cl2 gas using a molten NaCl–Na2CO3 electrolyte with a current efficiency of above 80 pct at 200 mA·cm-2, because the discharge of CO32− is significantly more favorable than that of Cl− at the graphite anode. Furthermore, the reduction of Na+ on the liquid Pb electrode happens at a potential more positive than the reduction of pure Na. The diffusion coefficient of Na in liquid Pb is measured as 3.22 × 10−4 cm2 s−1 at 750 °C by the galvanostatic intermittent titration technique (GITT), and the simulated electrolysis current density is 200 mA cm−2. Moreover, the prepared Pb–Ca–Na–Al using the electrolytic Na-Pb alloys achieves a significant mechanical strength improvement (27 pct increase of the hardness, 60 pct increase of the creep resistance). Overall, molten salt electrolysis offers a clean and efficient method for preparing various Pb alloys for next-generation LABs and other applications.