Plating System for Lightweight Valve-Regulated Lead Acid Batteries

The objective of the proposed work is to develop and demonstrate a pilot-scale lead plating process to make lightweight grids for valve-regulated lead acid aircraft batteries. The lightweight grids consist of an aluminum core that is plated with a thin layer of lead or lead-tin alloy. The objective of Phase I is to determine the technical and economic merits of alternate manufacturing methods that are capable of producing grids of the required quality and quantity. A manufacturing capability equivalent to 25 batteries per day will be targeted for the pilot-scale operation. This capacity is sufficient to meet the near term demand of military aircraft that currently use VRLA batteries. The preferred manufacturing method will be selected and detailed in Phase I and will serve as the basis for follow-on work in Phase II.