Barite (BaSO4) is a common additive in lead–acid
batteries, where it acts as a nucleating agent to promote the reversible
formation and dissolution of PbSO4 during battery cycling.
However, little is known about the molecular-scale mechanisms that
control the nucleation and cyclic evolution of PbSO4 over
a battery’s lifetime. In this study, we explore the responses
of a barite (001) surface to cycles of high and low lead concentrations
in 100 mM sulfuric acid solution using in situ atomic force microscopy
and high-resolution X-ray reflectivity. We find that PbSO4 epitaxial films readily nucleate on the barite surface, even from
solutions that are undersaturated relative to bulk PbSO4. Despite this, barite (001) proves to be an ineffective nucleator
of bulk PbSO4, as multilayer growth is suppressed even
in highly supersaturated solutions. Instead, we find evidence that
Pb2+ ions can directly exchange with Ba2+ to
create mixed (Ba,Pb)SO4 surfaces. These chemically mixed
surfaces do not host PbSO4 monolayers as readily as pristine
barite, and the original reactivity is not regained until a fresh
surface is re-established by aggressive etching. Our results can be
partly explained by traditional models of thin-film growth, which
predict a Stranski–Krastanov (S–K) growth mode, where
monolayer films are stabilized by a reduction in surface energy, but
multilayer growth is inhibited by epitaxial strain. Complementary
density functional theory calculations confirm the basic energetic
terms of the model but also show evidence for thickness-dependent
energetics that are more complex than would be predicted from traditional
models. The experimental results are better understood by extending
the model to consider the formation of mixed surfaces and films, which
have reduced strain and interfacial energies relative to pure films
while also being stabilized by entropy of mixing. These insights into
nonstoichiometric heteroepitaxy will enable better predictions of
how barite affects PbSO4 nucleation in battery environments.