A new powder rolling process for manufacturing current-collector sheets for lead-acid batteries has been developed. Gas-atomized lead-tin and lead-tin-calcium alloy powders obtained by a rapid solidification process in air were employed as raw materials for the powder rolling process. The corrosion behavior of powder-rolled lead-tin alloys with various compositions of tin has been investigated. A dipping corrosion test of square plain sheets of the alloys was performed in H2SO4 at 75 degrees C. The test was repeated up to 20 cycles with each cycle consisting of a controlled 10 mA cm(-2) oxidation current for 6 h and a rest under open circuit voltage for 6 h. The extent of corrosion-elongation and the appearance of the corroded surface of the tested specimens were the main observations. The corrosion-elongation of the corroded sheet of a powder-rolled lead alloy containing 1.5 wt% tin with ca. 200 mu m initial thickness was less than 5%, whereas that of the corroded sheet of the cast-rolled lead alloy containing 1.5 wt% tin with the same initial thickness was 25-30% under the same corrosion test conditions. The corroded powder-rolled sheet of the 1.5 wt% tin lead alloy has uniform corrosion, but the cast-rolled sheet of lead alloy containing 1.5 wt% tin was much distorted and was perforated by the corrosion. Intergranular corrosion of the powder-rolled lead-tin alloys was much suppressed as compared with that of the cast-rolled lead-tin alloys. (C) 2008 Elsevier B.V. All rights reserved.