The effects of geometrical and process variables on the quality of cast-on-strap joints

An automated laboratory-scale, cast-on-strap joining process for lead/acid batteries has been developed. This allows tight control of relevant casting parameters such as strap mould and metal temperature, lug immersion speed, and the time between strap filling and lug entry into the molten strap. Th...

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Bibliographic Details
Published in:Journal of power sources 1996, Vol.59 (1), p.71-79
Main Authors: Cook, S.M., Lakshmi, C.S., See, J.B., Rice, D.M.
Format: Article
Language:English
Subjects:
Alloying
Antimony
Antimony alloys
Applied sciences
Cast-on-strap
Composition effects
Direct energy conversion and energy accumulation
Electrical engineering. Electrical power engineering
Electrical power engineering
Electrochemical conversion: primary and secondary batteries, fuel cells
Exact sciences and technology
Grid alloys
Lead
Lead alloys
Lead/acid batteries
Liquid metals
Metal casting
Quality control
Thermal effects
Tin
Tin alloys
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Description
Summary:An automated laboratory-scale, cast-on-strap joining process for lead/acid batteries has been developed. This allows tight control of relevant casting parameters such as strap mould and metal temperature, lug immersion speed, and the time between strap filling and lug entry into the molten strap. The joining of lead-antimony or lead-tin strap alloys with lead-antimony or lead-calcium-tin lugs is studied. It is found that lead-tin is not suitable as a strap alloy for the alloy combinations and joining conditions that have been investigated. Penetration depth of the lug into the strap is found to be critical and may be optimized for a given lug thickness under fixed process conditions. The joint quality improves with a deeper penetration of the thicker lugs for the geometrical configurations studied in this work. It is far easier to form a sound joint with thin lugs as these are not as sensitive as thick lugs to variations in the joining conditions.
ISSN:0378-7753
1873-2755
DOI:10.1016/0378-7753(95)02304-6