Lead and lead alloys foams production

Low-cost techniques for the manufacturing of lead and lead-alloys foams have been investigated in this work. In particular the “sintering and dissolution process” (SDP) and “replication process” (RP) have been focused and discussed. The effects of some process parameters have been investigated too: powder compacting pressure, composition of the base metal, granulometry, sintering time and temperature. Spherical urea and NaCl have been employed in the SDP method. In the replication process the melt viscosity has been found the main parameter. Furthermore melt infiltration in the NaCl particles has been found much easier if external pressure is applied. Lead recovery and recycling of exhaust batteries into foam-based electrodes has been examined too with a novel method for the direct conversion of Pb scrap into lead foam.