So, what's likely to happen if I put a 600mAh Ni-MH battery pack in a device (cordless phone in this case) that's expecting a 400mAh Ni-Cd pack?
Right now it gives the impression of working - the Ni-MH pack seems to be taking a charge and isn't getting hot (yet). But I've read elsewhere that under charge Ni-Cd cell voltage will peak and then drop off, whereas Ni- MH cell voltage will simply level off - so potentially a charging circuit designed for Ni-Cd might look for that drop and keep on charging a Ni-MH cell until it eventually goes bang. What I don't know is if the charging circuit typically found in small consumer devices (as mentioned above, in this case a phone) is that clever...
I had a spare Ni-MH pack and so cut its plastic sleeve open, along with the dead Ni-Cd pack, and there's no cleverness in the packs themselves, just three cells in each along with a wire (such that the wires to the outside world come out on the same side of the pack, but which also could be designed to work as a fusible link, I suppose).
cheers
Jules