Lead-calcium intermediate alloy was prepared by fused salt electrolysis and further smelled into commercial alloys suitable for positive and negative grids of maintenance-free lead-acid batteries. Necessary protective measures were taken to ensure the Ca-contents in the alloys. The mechanical properties and corrosion resistance of various alloys of different compositions were determined. Electron-beam microprobe analysis and metallographical analysis were carried out to obtain suitable recipes and to explain the effect of Ca-content on the alloy performance.