Browse Topic: Thermal runaway

Items (202)
Find
Thermal and Emission Characterization of Cylindrical Lithium-Ion Batteries under Thermal Abuse Using a Climate Chamber2026-37-0023To be published on 06/09/2026
Thermal safety in lithium-ion batteries is a critical aspect due to their increasing use in energy storage systems and electric vehicles. To investigate thermal abuse conditions, numerous studies on cylindrical cells employ specialized equipment to accurately measure temperature and pressure during thermal runaway events. However, such tests typically require robust, dedicated, and high-cost facilities, which limit their availability in conventional laboratory environments. In this context, the present study proposes and evaluates an experimental methodology based on the use of a climate chamber combined with an instrumented reduced-volume container, to reproduce severe external heating conditions. The thermal behavior and gas emissions associated with thermal runaway events were characterized in six cylindrical lithium-ion batteries of two different chemistries. Initially, the experimental setup was validated using a reference cell to verify the methodology and the measurement systems
Penagos Vásquez, Diego Alejandro, Marco-Gimeno, Javier, Monsalve-Serrano, Javier, Garcia, Antonio, Perez Balastegui, Jose
Advancing Safe Battery Design through Experimental Cell Characterization of Thermal, Electrical and Mechanical Properties2026-01-0408To be published on 04/07/2026
Lithium-ion batteries are critical to Electric Vehicles (EV) and grid-scale energy storage. Safe design of battery systems relies on accurate simulation of thermal runaway under electrical, thermal, and mechanical abuse. A predictive battery simulation requires characterization of electrical, thermal, and mechanical properties at the full cell and cell-component levels. In this study, a commercial cell from an EV was disassembled, and tested to support both homogenized and detailed computational models. At the cell level, electrical properties were characterized using Hybrid Pulse Power Characterization (HPPC) testing to assess the cell’s power capability. Full cell compression tests were conducted to characterize mechanical behavior under deformation and used to develop a multi-physics homogenized cell model. On the other hand, detailed cell modeling that includes different component layers could help users understand localized cell integrity under mechanical deformation. At the
Challa, Vidyu, Rostami-Angas, Masoud, kong, Kevin, Wang, Leyu, Reichert, Rudolf, Kan, Cing-Dao
Simplified Thermal Runaway Propagation Modeling to Design a Mass Optimized Battery Pack2026-01-0404To be published on 04/07/2026
This paper presents a simplified approach to model thermal runaway propagation in a multi-cell battery pack, with the goal of designing a safe and lightweight pack for mass-sensitive applications. The key parameters which characterize single-cell thermal runaway, including heat release profile, apparent cell emissivity and mass loss, were extracted from empirical nail penetration tests. This characterization was used to drive a three-dimensional thermal model of a 19-cell hexagonal sub-pack with a center trigger cell. To enable rapid design exploration, a symmetry-based computationally simplified domain was used for a full-factorial Design of Experiments (DOE) varying cell spacing, epoxy thickness, heat spreader thickness, and cup geometry. The DOE results were used to identify dominant heat-transfer mechanisms, capture main and interaction effects, and determine mass-efficient design levers governing peak-neighbor cell temperature during propagation. Insights from the DOE study
Kalyankar, Apoorv, Owen, Elliot, Strohmaier, Kyle, Mardall, Joseph
Predictive Modeling and Sensitivity Analysis of Thermal Runaway in 800V Lithium-Ion Battery Module Using DFSS Methodology2026-01-0124To be published on 04/07/2026
Thermal runaway in high-voltage lithium-ion battery modules should focus on critical safety and design challenges in electric vehicle applications, which need predictive methods that enhance passenger safety and support regulatory compliance. The primary purpose of a lithium-ion battery in an electric vehicle is to provide reliable energy storage while maintaining safe operation under different operating conditions. This study proposes a Design for Six Sigma (DFSS) methodology to virtually predict and correlate thermal runaway and its propagation in an 800V high-power lithium-ion battery pack module. Conventional propagation analysis relies heavily on physical testing, whereas the DFSS-based virtual framework enables cost-effective evaluation at early design stages. Input factors included are heat transfer pathways, which are sensitive to the temperature changes, as well as thermal propagation time. Control factors are the design or process parameters that engineers use to establish
Dixit, Manish, Raja, Vinayak, Gudiyella, Soumya
Modeling Non-Uniform Temperature Distribution in Lithium-Ion Batteries2026-01-0120To be published on 04/07/2026
Non-uniform temperature distribution within lithium-ion battery cells is a critical challenge that accelerates degradation, compromises safety, and reduces pack-level performance in electric vehicles (EVs). This work focuses on modeling and minimizing these thermal gradients through the structured optimization of a liquid-based Battery Thermal Management System (BTMS). A one-dimensional transient thermal model is developed to capture the axial temperature differentials (ΔT) in a cylindrical cell under dynamic drive-cycle loading, incorporating detailed heat transfer from the cell interior through thermal interface materials (TIM) and an aluminum cooling plate to the coolant. Using a Design for Six Sigma (DFSS) approach with an L18 orthogonal array, key control factors—including coolant flow rate, inlet temperature, TIM properties, and plate geometry—are systematically analyzed to identify configurations that optimally balance low average temperature with minimal internal temperature
El-Sharkawy, Alaa, Asar, Mona, Serpento, Stan, Sheta, Mai
Application of DFSS for Optimizing Thermal Protection in Electric Vehicles during Battery Thermal Runaway Events2026-01-0142To be published on 04/07/2026
Battery thermal runaway is a major safety concern in electric vehicles because of the extreme heat and hazardous gases released during cell failure. These venting events can quickly raise the temperature of the battery enclosure and cabin floor, threatening occupant safety. To address this challenge, this study employs the Design for Six Sigma (DFSS) methodology to design and optimize a thermal protection system that delays and limits heat transfer to the cabin. A physics-based transient heat-transfer model was combined with DFSS principles to systematically evaluate insulation materials, shield layouts, surface emissivity, and layer geometry. An L-18 orthogonal array was used to identify key parameters and quantify their influence on thermal robustness. The optimized architecture reduced cabin-floor temperature rise under severe runaway conditions (600–900 °C vent gas), meeting occupant-egress safety requirements. Findings confirm DFSS as an effective framework for developing high
El-Sharkawy, Alaa, Asar, Mona, Taha, Nahla, Sheta, Mai
Thermal Insulation Materials Used in Battery Pack Assembly: A Review of Materials, Test Methods, and Key Considerations2026-01-0406To be published on 04/07/2026
Electric vehicle (EV) battery packs have undergone substantial advancements in recent years, driven by engineering design improvements, material innovations, and increasingly stringent regulatory enforcement. These developments have enabled battery packs to become more energy-dense, which is essential for extending driving range and improving overall vehicle performance. However, with increased energy density comes a higher severity of thermal events, such as thermal runaway, which continues to raise concerns regarding vehicle safety, reliability, and long-term durability. This review highlights the critical role that thermal insulation materials play in mitigating the impact of such thermal events within EV battery systems. It presents an overview of commonly used thermal insulation materials, emphasizing their chemical composition, thermal resistance, and mechanical integrity under extreme conditions such as high temperatures and physical stress. The ability of these materials to
Ng, Sze-Sze, Dhyani, Abhishek, Gorin, Craig, Jeon, Junho, Nuguri, Sravya, Repollet Pedrosa, Milton, Rylski, Adrian, Shete, Abhishek, Steinbrecher, Jacob, Thomas, Ryan
Guidelines for Interior Material Selection to Enhance Thermal Safety in Electric Vehicles2026-01-0249To be published on 04/07/2026
The advancement of electric vehicles necessitates a rigorous focus on passenger cabin safety, particularly concerning the severe thermal hazard of a lithium-ion battery thermal runaway. Unlike internal combustion engine vehicles, electric vehicles require interior materials that provide superior thermal resistance to slow heat propagation, delay autoignition, and minimize smoke and toxic gas emissions, thereby securing a survivable evacuation window. This paper examines the application of the lumped-capacitance thermal model and the derived thermal time constant (τ) as a foundational framework for evaluating and selecting cabin materials. This approach enables a quantitative, physics-based ranking of materials—including seat composites, sound-deadening layers, electrical insulation, and carpet assemblies—based on their intrinsic ability to delay their own temperature rise under transient heat flux. By integrating materials with a high τ and elevated critical failure temperatures, this
El-Sharkawy, Alaa, Taha, Nahla, Asar, Mona, Sheta, Mai
Towards Plating-Free Charging: Lightweight Prediction of Lithium Plating Current Limits2026-01-0387To be published on 04/07/2026
Lithium plating is a critical barrier to fast charging in electric and hybrid-electric vehicles, occurring at high state of charge (SOC) or low temperatures when Li+ deposits as metallic lithium on the anode surface instead of intercalating into graphite. At low temperatures, plated lithium may form dendrites that pierce the separator and trigger thermal runaway, while at high SOC, irreversible plating accelerates capacity fade by depleting cyclable lithium. Despite extensive study, lithium plating remains difficult to incorporate into battery management systems (BMS) due to computational complexity and the challenge of real-time detection, leading to reliance on conservative lookup maps. This work presents a lightweight empirical model for predicting plating-free charging limits in lithium nickel manganese cobalt (NMC) cells. A high-fidelity pseudo-2D electrochemical model was exercised across a wide range of charge rates and temperatures to capture the coupled effects of SOC
Sundar, Anirudh, Ghate, Atharva, Zhu, Qilun, Prucka, Robert, Barron, Morgan, Figueroa-Santos, Miriam
Effects of Obstacle Height and Vehicle Roll Behavior on Electric Vehicle Side Impact Safety2026-01-0405To be published on 04/07/2026
Electric vehicles (EVs) face unique safety challenges under pole side impact conditions, largely due to the presence of floor-mounted battery packs. Existing regulatory test procedures, such as FMVSS 214, primarily address occupant injury using full-height cylindrical obstacles. These procedures were originally developed for internal combustion vehicles (ICVs). However, real-world roadside crashes frequently involve obstacles of varying heights, such as guardrails, curbs, and median bases. While these obstacles pose limited risk to the passenger compartment, they can intrude into the battery pack and trigger thermal runaway. This study investigates the influence of obstacle height on EV pole side impacts. Finite element simulations of a commercially available sedan were conducted against rigid obstacles of different heights. Results reveal a non-monotonic trend of battery intrusion governed by the interplay between rollover dynamics and structural stiffness. Theoretical analyses were
Ma, Chenghao, Xing, Bobin, Zhou, Qing, Xia, Yong
Standalone Battery Pack Thermal Behavior Simulation and Experimental Correlation in a Controlled Environment2026-01-0125To be published on 04/07/2026
Battery thermal management is crucial for ensuring the safety, efficiency, and longevity of lithium-ion battery packs, particularly in electric vehicles (EVs). The primary purpose of a lithium-ion battery in an electric vehicle is to store and provide electrical energy for vehicle propulsion while maintaining safety under different operating conditions. This work proposes a thermal correlation between 1D CFD simulation and experimental test data under passive environmental heat exchange conditions without active coolant flow of a battery pack comprising four modules. An environmental exchange test was conducted using a 50% state of charge (SOC) battery pack, which is stabilized at 25°C to assess passive heat dissipation, thermal soak behavior, temperature distribution, and potential thermal runaway risks. The simulation predictions correlate well within a 1.5°C range compared to test results using ambient temperature and flow inputs, which confirms the reliability of the modeling
Nayaka, Sateesh Kumar, Dixit, Manish, Gudiyella, Soumya
A CFD Based Multi-Physics Modeling Approach to Predict Vent Gas Flow Paths Due to Can Melting during Prismatic Cell Thermal Runaway2026-01-0407To be published on 04/07/2026
As the automotive industry increasingly adopts high-energy-density batteries, ensuring vehicle safety against catastrophic thermal runaway (TR) has become paramount. Predicting the complex failure sequence of prismatic cells, requires high-fidelity simulation tools that can capture tightly coupled physical phenomena. This paper presents a comprehensive, three-dimensional multi-physics Computational Fluid Dynamics (CFD) framework designed to simulate the entire TR event. The simulation originates with a multi-step Arrhenius chemical kinetics model to calculate the heat and gas generated by the primary exothermic reactions. This process drives a rapid increase in internal temperature and pressure, which is resolved by the model’s fluid dynamics solver. The initial vent opening is triggered when this internal pressure exceeds a predefined mechanical burst threshold, simulating a realistic seal rupture. Concurrently, a Conjugate Heat Transfer (CHT) analysis calculates the temperature
Mukherjee, Swarnava, Schlautman, Jeff, Srinivasan, Chiranth
Understanding the Effects of Process Parameters on the Dispense Uniformity of Elastomeric Silicone Coating Material for Automotive Manufacturing.2026-01-0239To be published on 04/07/2026
As electric vehicle (EV) manufacturing scales, innovative approaches have been evolving for battery fire protection materials to mitigate thermal runaway hazards, including fire and blast protective coatings. These materials often exhibit high-viscosity and must be deposited with uniform thickness and stable geometry to ensure reliable thermal barriers and battery pack integration. In practice, coating uniformity (uniform thickness, edge fidelity, and minimal sag/run prior to cure) is highly sensitive to dispense conditions, including nozzle slot width, nozzle length, effective dispense height (stand‑off), nozzle sweep speed, and volumetric dispense rate. Establishing robust process understanding early is therefore essential to avoid start‑up scrap, rework, and variability downstream. This paper presents a combined computational and experimental methodology to optimize and de‑risk dispensing of elastomeric battery fire protection (BFP) coatings. We develop a physics‑informed modeling
Hossain, Arif, Repollet Pedrosa, Milton H., Norquest, Kade, Mcmichael, Jonathan, Ng, Sze-Sze, Aradhyula, Pranavi, Thomas, Ryan, Gorin, Craig, Dietsche, Laura, Kenney, James A.
Electro-Thermal Co-Optimization of Battery Modules Based on 3D Thermal Model Simulation2026-01-70292/27/2026
As an important energy storage device and the power source for key equipment such as automobiles and drones at present, lithium-ion batteries generate a substantial amount of heat during their operation. Without an effective cooling system, the temperature of the battery module can rise, significantly impacting the battery's service life and safety performance. Therefore, automotive battery modules require an efficient battery thermal management system to regulate heat dissipation and extend battery life. We note that many existing vehicle battery thermal management systems focus solely on the surface temperature of the battery. However, uneven heat distribution within the battery can also lead to issues such as unbalanced aging and thermal runaway safety hazards. Thus, we specifically emphasize the internal temperature distribution of the battery, focusing on internal temperature optimization design and simulation. Taking the battery module equipped with the third-generation NCM 9
Wu, Jiayi, Zheng, Bowen, Kang, Mengran, Zhan, Wenwei, Qi, Ji, Yi, Yong
A Thin-Film Flexible Temperature-Strain Multimodal Sensor for Lithium-Ion Battery Monitoring Based of Laser Direct Writing2026-01-70262/27/2026
Multimodal sensors, capable of simultaneously acquiring multiple physical or chemical signals, have shown broad application potential in fields such as health monitoring, soft robotics, and energy systems. However, current multimodal sensors often suffer from complex fabrication processes and signal decoupling challenges, which limit their practical deployment. To address these issues, this work presents a thin-film temperature–strain multimodal sensor (FTSMS) fabricated via laser processing. The temperature-sensing unit, based on the Seebeck effect, achieves a sensitivity of 9.08 μV/°C, while the strain-sensing unit, utilizing BaTiO₃/AlN@PDMS as the sensitive layer, exhibits a gauge factor (GF) of 43.2. By integrating distinct sensing mechanisms (thermovoltage for temperature and capacitance change for strain), the FTSMS enables self-decoupled measurements over 20–90 °C. Applied in LIB monitoring, it successfully captures real-time temperature and strain variations during charge
Wang, Ziwei, Li, Zhenglin, Gao, Yang, Xuan, Fuzhen
Research on the Repeatability of Thermal Runaway of Lithium-Ion Batteries Triggered by Heating Wires2026-01-70272/27/2026
Due to limitations in available battery samples and testing costs, lithium-ion battery thermal runaway experiments are not practical to repeat multiple times, and the reliability of experimental results is frequently questioned. To systematically evaluate the repeatability of the heating wire-triggered method in thermal runaway tests, this study investigates two types of commercial 18650 cylindrical batteries with NCM/graphite chemistry under different heating power levels and health conditions. The results indicate that under the same heating power, batteries of the same type exhibit good repeatability in thermal runaway onset time and onset temperature, with the consistency of onset time outperforming that of onset temperature. As the heating power increases, the onset time of thermal runaway decreases significantly, while the variation in onset temperature remains relatively small. Compared to fresh batteries, aged batteries show reduced variability in thermal runaway
Wang, Jia, Yan, Hongtao, Zhang, Yuemeng, Lin, Chunjing, Lao, Li
Revealing the Thermal-Gas Stability of Lithium Ion Batteries under Low-Temperature Cyclic Aging2026-01-70282/27/2026
With high energy density and long cycle life, lithium-ion batteries (LIBs) are currently the most promising electrochemical devices for electric vehicles and energy storage. However, the safety and reliability of LIBs can be significantly compromised in low-temperature cyclic due to anode lithium plating and other factors which are still unclear. Therefore, it is essential to reveal the thermal-gas stability of LIBs under low-temperature cyclic. This study investigates the thermal runaway (TR) characteristics and gas production characteristics after TR of 18650-type NCA LIBs across four states of health (SOH), from 100% to 70%. Using Glove box, Electrochemical impedance spectroscopy, Scanning electron microscope, X-ray photoelectron spectroscopy, Accelerating rate calorimetry, and Gas chromatography, the research identifies critical trends in temperature rate, gas composition and explosion risk. After around 150 cycles, there is a significant and rapid decline in capacity. The internal
Wang, Hailong, Wu, Senming, Luan, Weiling, Chen, Haofeng
Design and Performance Study of Highly Reliable Marine Battery Based on Solid Polymer Electrolyte2026-01-70352/27/2026
Currently, electric propulsion is playing an increasingly important role in marine propulsion systems.Lithium metal batteries are new-generation high-performance energy storage system with development prospect. Traditional flammable and volatile organic liquid electrolytes pose a risk of thermal runaway, while solid-state lithium metal batteries using solid electrolytes have significant advantages in energy density and safety, and are considered the most promising mobile power sources. Among numerous solid electrolyte systems, polymer solid electrolytes have excellent flexibility, good interface compatibility, and good processing characteristics, which have attracted the attention of researchers. Polyurethane (PU) is a common polymer with high mechanical strength and a flexible and adjustable molecular structure, making it one of the best choices for polymer electrolyte matrices. Based on the structural design of polyurethane polymers, this paper explores polycaprolactone type
Yuan, Meng, Tang, Qing, Yu, Gongye
Transient Modeling and PID-Controlled Nanofluid Cooling for Enhanced Thermal Management in Proton Exchange Membrane Fuel Cells2026-01-70302/27/2026
Appropriate thermal management system is important for the lifespan and safety of proton exchange membrane fuel cells (PEMFCs). A comprehensive thermal management system for PEMFC was proposed through finite element model (FEM), control optimization and nanofluid cooling. An 0D-3D coupled thermal model for energy balance and local temperature field analysis was established. By coupling internal heat transfer dynamics with Proportional-Integral-Derivative (PID) control logic, the optimal parameter combination was determined as Kp=-1 m/(s⋅K), Ki=-0.1 m/(s2⋅K) and Kd=0 (m/K). Additionally, the nanofluid coolant revealed a concentration-dependent trade-off between enhanced thermal performance and decreased flow performance. In the range of 0-15% of the nanofluid concentration, the Reynolds number and pressure drop increase with the increase of the concentration of the nanofluid, while in the range of 16-20%, the Reynolds number decreases with the increase of the concentration of the
Zhang, Xiaoliang, Deng, Yikang, Zhao, Yanli, Wang, Qi, Luo, Shengfeng
Lithium Plating-Induced Surface Pressure Evolution in Lithium-Ion Pouch Cells under Rigid Constraints2026-01-70132/27/2026
In practical applications, power cells face a mix of external influences such as temperature variations and structural limits (rigid constraints) that trigger intricate electrochemical and mechanical reactions. This study systematically explores the temporal evolution of surface pressure in lithium-ion pouch cells subjected to rigid mechanical constraints under varying thermal conditions, with a specific focus on the interplay among mechanical stress, lithium intercalation, and lithium plating. To investigate the battery’s electrochemical and mechanical responses, this work integrates experimental measurements with an electrochemical–mechanical coupling model. The analysis is performed under initial loads of 0.3, 0.5, and 1.0 MPa at 25 °C (ambient temperature) and 0 °C (representative low-temperature condition). At 25 °C, surface pressure followed a two-stage pattern: first, stress relaxation occurred, followed by a shift into quasi-steady cycling (cycle-to-cycle variations are minimal
Du, Yingyue, Chen, Ying, Luan, Weiling, Chen, Haofeng
Fault Diagnosis Method of Lithium-Ion Batteries Based on OCSVM and RLMQD Algorithms2026-01-70202/27/2026
To address the challenges of recognizing abnormal states, detecting subtle early warning signs, and quantifying fault severity in scenarios involving simultaneous multiple faults in lithium-ion batteries, this study proposes a dual-layer fault diagnosis framework that integrates One-Class Support Vector Machine (OCSVM) and Robust Local Mahalanobis Distance Quantile (RLMQD) algorithm. First, a three-dimensional multi-scale feature space, incorporating voltage, kurtosis, and voltage change rate, is constructed to detect abnormal battery states via OCSVM and dynamically filter abnormal time periods with improved adaptability. Second, a computationally efficient RLMQD-based quantization algorithm is developed, which employs a small-scale sliding window and adaptively selects healthy cells to construct reference distributions. By incorporating low-quantile thresholds, the algorithm enhances early abnormality detection and significantly reduces false positives. Subsequently, fault severity
Wei, Fuxing, Yang, Libing, Wang, Zonglei, Xia, Xuelei, Shen, Jiangwei, Chen, Zheng
Research on State of Charge Estimation Method for Lithium Iron Phosphate Batteries Based on Expansion Force2026-01-70402/27/2026
To enhance the accuracy and robustness of State of Charge (SOC) estimation for lithium iron phosphate (LiFePO₄) batteries and to overcome the limitations of traditional electrical signal-based methods—such as cumulative errors in Coulomb counting and the need for rest periods in open-circuit voltage (OCV) methods—this study proposes a novel SOC fusion estimation algorithm based on mechanical expansion force signals. Addressing the challenge of feature extraction, a model framework integrating the Sparrow Search Algorithm (SSA), Least Squares Support Vector Machine (LSSVM), and Adaptive Extended Kalman Filter (AEKF) is developed. The state equation is constructed via Coulomb counting, while SSA optimizes the LSSVM to establish an observation model centered on expansion force as the input. The AEKF is employed to achieve real-time, precise SOC prediction. Experimental validation under varying temperatures (25°C, 35°C) and dynamic driving cycles (FUDS, UDDS) demonstrate that this fusion
Du, Jinqiao, Rao, Bo, Tian, Jie, Wu, Yizeng, Xu, Haoming, Jiang, Jiuchun
Data-Driven Capacity Estimation Method for Retired Lithium-Ion Batteries Based on Electrochemical Impedance Spectroscopy2026-01-70152/27/2026
With the rapid expansion of global electric vehicles (EVs) deployment, the echelon utilization of retired lithium-ion batteries (LIBs) has emerged as a critical issue. Although these batteries typically retain over 70% of their initial capacity and remain suitable for stationary energy storage systems, the substantial variability in aging states poses safety risks. Conventional capacity estimation methods are often time-intensive and costly, while data-driven approaches face challenges from complex degradation mechanisms and limited historical usage data. This study uses the electrochemical impedance spectroscopy (EIS) method to create a model that estimates the capacity of retired batteries. EIS offers fast measurement, requires no historical cycling data, and provides rich state-of-health (SOH) information. An EIS dataset was acquired from 18650-type LFP and NCM cells aged under multiple cycling conditions. The real part and magnitude of the impedance spectra were extracted as input
Hou, Zhengyu, Luan, Weiling, Sun, Changzheng, Chen, Ying
Study on the Evolution of Precise Internal Short Circuit Damage in Li-Ion Batteries2026-01-70252/27/2026
One primary cause of NEV fires is thermal runaway initiated by internal short circuit in power batteries, leading to subsequent thermal diffusion throughout the battery system. Severe internal short circuit damage can precipitate thermal runaway phenomena in lithium-ion batteries, potentially culminating in fire incidents involving electric vehicles. Although mild internal short circuit may not immediately induce thermal runaway, continuous charge and discharge cycling can exacerbate such conditions, progressively elevating risks associated with thermal runaway and other pertinent safety hazards. Conventional safety testing methodologies, employing techniques such as crushing and nail penetration to simulate internal short circuit, often amplify the extent of these shorts and fail to accurately replicate less severe, deeper internal short circuit. Additionally, methods incorporating foreign objects like nickel pieces for simulating internal short circuit necessitate battery disassembly
Sun, Zhipeng, Ma, Tianyi, Han, Ce, Wang, Fang, Ren, Gaohui
Analysis of Heat Transfer in Microchannel Heat Sink with Porous Fins for Battery Cooling Module2026-01-70172/27/2026
Heat sinks are essential cooling components in the battery thermal management systems (BTMS). Porous fin microchannel heat sinks can achieve high heat transfer rates in confined spaces, offering significant potential for practical applications. In this study, a modified-porous fin microchannel heat sink for BTMS is numerically simulated to examine its fluid dynamics and thermal exchange properties. By partially and uniformly filling metal foam in solid fins, the temperature is reduced, the Nusselt number is increased, and the comprehensive performance is enhanced. Compared with solid fins, the modified design is shown to yield a maximum Nusselt number improvement of 153.6%, accompanied by a peak performance evaluation coefficient reaching 1.92. Thermal analysis is conducted by considering both structural optimization and coolant flow behavior. Effects of metal foam filling width and height are investigated. The fluid dynamics and thermal exchange properties of the modified structure
Zhang, Liyuan, Lai, Huanxin
Effects of Salt Spray Corrosion on Thermal Runaway of Lithium-ion Batteries2026-01-70312/27/2026
The increasing electrification of marine equipment underscores the need to ensure lithium-ion battery (LIB) safety in corrosive environments. Unlike land applications, shipboard batteries are continuously exposed to salt spray, which accelerates material degradation and raises the risk of thermal hazards. Thus, this study investigates the effects of salt spray corrosion on the electrochemical performance and Thermal runaway (TR) behavior of commercial 18650-type ternary LIBs. Through charge-discharge calorimetry and cone calorimeter tests, variations in voltage response, capacity fade, mass loss, and heat release rate were analyzed under different states of charge (SOC), states of health (SOH), and exposure durations. The results show that corrosion significantly accelerates electrode deterioration, leading to faster capacity decline and voltage plateau shifts. At higher SOH, casing rupture induced earlier TR with violent combustion, whereas at lower SOH, corrosion-induced energy
Tao, Liyanyu, Shi, Xinyuan, Yang, Qinyuan, Liu, Jiahao
Electro-Thermo-Mechanical Simulation and Machine Learning for Temperature Prediction of Lithium-Ion Batteries under Mechanical Abuse2026-01-70412/27/2026
Lithium-ion battery safety under mechanical abuse has become a critical challenge with the widespread adoption of electric vehicles. This study proposes a predictive framework combining multi-physics finite element simulation and machine learning to estimate the temperature rise of lithium-ion cells under impact conditions. An Electro-Thermo-Mechanical (ETM) coupled model was established in LS-DYNA to simulate the effects of impactor radius, velocity, and ambient temperature on internal heat generation. Using a full factorial sampling design, 125 simulation scenarios were generated to extract maximum temperature data. These data were used to train and compare several regression models, including Support Vector Machines (SVM), Decision Trees (DT), Back Propagation Neural Networks (BPNN), and Random Forests (RF). A Stacking ensemble model integrating these base learners achieved the highest prediction accuracy, with an R2 of 0.996 and RMSE below 0.5. Performance remained robust even
Wan, Cheng, Zhan, Zhenfei, Chen, Qiuren
Rapid Battery RUL Prediction under Different Fast-Charging Protocols via Domain-Adaptive Deep Learning and Model Compression2026-01-70032/27/2026
Accurate and rapid remaining useful life (RUL) prediction of batteries under various extreme conditions is crucial for battery management systems. However, existing methods often face challenges such as limited datasets under extreme conditions, high model complexity, and weak interpretability. Therefore, this paper proposes a hybrid framework based on pruning domain-adaptive convolutional neural networks (CNN) and long short-term memory (LSTM) to study RUL prediction under different fast-charging conditions using the MIT dataset. First, four voltage-related feature matrices are extracted. Using maximum mean discrepancy (MMD) constraints, the CNN-LSTM is trained with source domain and limited target domain data to align distributions. Neuron pruning is then applied to the fully connected layer to compress the model. Results demonstrate that under sparse target domain data, the domain adaptation approach achieves significantly lower prediction errors than fine-tuning. The pruned model
Huang, Mingyue, Chen, Hongxu, Luan, Weiling
Risk of Safety Abuse Testing and Safety Environment Control Strategies for Lithium-Ion Batteries2026-01-70082/27/2026
With the vigorous development and technological iteration of the new energy vehicle industry, the strategic position of inspection, certification, R&D and testing in the industrial chain has become increasingly prominent. As the core energy storage component of new energy vehicles, the potential safety risks and environmental hazards in the testing process of power batteries are particularly worthy of vigilance. Based on more than ten years of operational practice in battery laboratories, this paper summarizes experience and lessons in depth, focusing on problems such as smoke, fire, explosion and release of toxic and harmful substances caused by thermal runaway of batteries in lithium-ion battery safety abuse tests. From the dimensions of risk characteristics of safety abuse tests, laboratory security design, and laboratory environmental protection facilities, it systematically expounds the risk prevention and control strategies and environmental protection measures for lithium-ion
Ren, Gaohui, Liu, Lei, Jiang, Chenglong, Sun, Zhipeng, Chen, Liduo
A Hierarchical Fault Detection Method for Lithium-Ion Batteries in Real-World Vehicle Applications2026-01-70062/27/2026
With the rapid expansion of the electric vehicle market, the safety of lithium-ion batteries, which serve as the main power source, has become a critical concern. Current mainstream methods for battery fault detection generally face a technical bottleneck of struggling to balance high accuracy with a low false alarm rate. Furthermore, constrained by algorithmic complexity and data processing efficiency, detection speeds often fail to meet the practical demands of real-time monitoring. As a result, developing more efficient and accurate fault detection technologies has emerged as a key challenge urgently needing to be addressed in the industry. This paper proposes a hierarchical fault detection framework for lithium-ion batteries that integrates voltage change characteristics with a Local Outlier Factor (LOF) scoring mechanism. The framework aims to achieve early identification and accurate diagnosis of abnormal battery states through multi-dimensional feature extraction and algorithmic
Gao, Zhengpeng, Gao, Pingping, Chang, Penghui, Liu, Gang, Wu, Ji
Thermal Runaway Characteristics of LMFP Hybrid Batteries at Different State of Charge2026-01-70192/27/2026
Lithium-ion batteries (LIBs) have drawn substantial scientific interest because of their impressive energy storage capabilities and long-term operational stability. In recent years, new battery material systems have emerged, among which LMFP (LiMnxFe1−xPO4) is regarded as a promising candidate for future battery development, combining high energy density with enhanced safety. However, research on the thermal runaway (TR) behavior of LMFP-based batteries remains scarce, leaving their cell-level safety unverified. This study modifies the conventional state of charge (SOC) classification method by measuring the oxidation state of cathode materials at specific voltages. By testing the thermal runaway (TR) temperature and gas release characteristics of LMFP hybrid batteries under different voltage states, it reveals the influence of cathode oxidation state on TR behavior. The results demonstrate that when the NCM (LiNi₀.₅Co₀.₂Mn₀.₃O₂) component remains unoxidized, the battery does not
Guo, Zhenquan, Wu, Senming, Luan, Weiling, Chen, Ying, Chen, Haofeng
A Pulsed-Charging-Current Heating Method for Lithium-Ion Batteries at Low Temperature2026-01-70042/27/2026
Lithium-ion batteries suffer from capacity degradation, lifespan attenuation, and power decline at low temperatures. Alternating-pulsed-current (APC) heating method is an effective solution for improving the low-temperature performance of batteries, but it still faces challenges in terms of low heating efficiency and energy consumption. This work proposes a pulsed-charging-current (PCC) heating method to address these issues. The effect of the PCC under various conditions, including frequency and amplitude, is investigated through experiments. According to the experimental results, the battery can be heated from -20 °C to above 7.5 °C within 15 minutes using the proposed PCC method, with a heating rate of 1.83 °C/min. Compared with the traditional APC heating method, the heating rate of the PCC method increases by 7.9%. During the 15-minute heating process, the battery capacity increased by 131.9 mAh on average, and the charging efficiency can be achieved 95% above. The proposed method
Xiao, Yuechan, Huang, Xinrong, Wu, Ze, Zhang, Yipu, Meng, Jinhao
Real-Time Fault Diagnosis and Reliability Analysis in Lithium-Ion BESS via Bayesian Fault Propagation Networks2026-01-70232/27/2026
The rapid integration of intermittent renewable energy sources (RES) poses significant operational challenges for modern power systems. Lithium-ion battery (LIB)–based battery energy storage systems (BESS) have become vital for grid stability and energy management. However, large-scale deployment of BESS has led to increasing incidents such as fires and explosions, raising serious concerns regarding their safety and reliability. To overcome the limitations of traditional reliability assessment methods—such as reliability block diagrams (RBD), fault tree analysis (FTA), and Markov models—this study proposes an integrated fault detection and reliability analysis framework that combines FTA, failure mode and effects analysis (FMEA), and a Bayesian Fault Propagation Network (BFPN). The framework systematically models fault propagation across component, subsystem, and system levels, dynamically updating the prior probabilities of basic failure events using a Gaussian Mixture Model (GMM) and
Yang, Zhan, Chen, Xiaobo, Zheng, Ruixiang, Li, Mian
Joint Estimation of State of Charge and Capacity throughout the Full Service Life Cycle for Li-Ion Batteries2026-01-70212/27/2026
Accurate SOC and capacity estimation is essential for the safe operation of lithium-ion batteries. However, model parameters drift due to temperature variations and aging. This study proposes a migration-model-based method for joint estimation of SOC and capacity over a wide range of temperatures and degradation levels. The WSPF algorithm identifies migration factors in real time and applies them to estimate SOC and capacity under nonlinear, non-Gaussian conditions. Validation under various test conditions demonstrates clear advantages. Compared to EKF, the migration-model-based algorithm reduces the maximum RMSE of SOC estimation to 0.55%. For capacity estimation, it achieves a maximum RMSE of 1.15%. The estimation accuracy remains high throughout temperature changes and aging, highlighting the robustness and applicability of the proposed method for real-world battery management systems.
Liu, Weiqiang, Chen, Zheng, Wei, Fuxing, Shen, Jiangwei
Enhancing EV Battery Safety: Progressive Crushing and Energy Absorption Technique2026-26-01891/16/2026
A crash energy absorption technique and method improve the safety and structural integrity of electric vehicle battery packs during collisions, complying with global regulations. This analysis details an assembly featuring a battery housing for mounting battery cells, a crash member connected to the battery housing's periphery, and flexural members linked to the crash member. The flexural members are designed to absorb impact forces by deforming and storing potential energy during sudden impacts. This approach ensures energy is stored within the flexural elements and then transferred to the battery cells through progressive crushing. The design effectively delays intrusion, enhances battery safety, and minimizes cell-level damage. This solution improves occupant safety and prevents thermal runaway incidents while maintaining the battery's overall performance and reliability in EVs.
Amberkar S, Sunil, Lakshman singh, Meenakumari, Bodaindala, Anil Kumar
Steel-Based Laminates for Lithium-ion Pouch Cell of Electric Vehicles2026-26-01861/16/2026
Aluminum foils have gained traction with EV battery manufacturers for their pouch cell format. Over the years, it has evolved as a material of choice, but it is still plagued by the issues of stress concentration and swelling due to lower strength and lower stiffness of base aluminum layer. Preliminary investigation revealed that laminates using steel foil material (thickness < 0.1mm) could be a potential candidate for EV pouch cell casing. Thus, steel-based laminate was developed meeting key functional requirements (e.g., barrier performance, insulation resistance, peel strength, electrolyte resistance, formable without cracking at edges, and heat sealing compliant). This innovative patented steel-based laminate [1] was further used to manufacture pouch cell prototypes (up to a maximum capacity of 2.8Ah) for key performance evaluation (e.g., cell cycling and nail penetration). The study paves the way for a low cost, sustainable and flexible yet strong steel-based laminate packaging
Singh, Pundan Kumar, Raj, Abhishek, Kumar, Ankit, Chatterjee, Sourabh, Verma, Rahul Kumar, Samantaray, Bikash, Gautam, Vikas, Pandey, Ashwani
Comprehensive Insights on Techniques for Managing and Preventing Thermal Runaway in EV Lithium-Ion Batteries2026-26-01711/16/2026
This paper presents a comprehensive investigation into the mechanisms, risks, and mitigation strategies associated with thermal runaway in lithium-ion batteries used in electric vehicles (EVs). It begins by emphasizing the urgency of the issue, identifying key vulnerabilities within EV battery systems that contribute to runaway events. A multiscale, stage-wise breakdown of thermal runaway progression is provided, illustrating how physical, chemical, and thermal interactions compound during failure scenarios. The study analyzes global incident data from 2000 to 2025, revealing trends in human health impacts, vehicle damage, and public safety concerns. Particular attention is given to how battery aging, manufacturing defects, and external abuse conditions elevate the likelihood and severity of thermal runaway. Current emergency response protocols and state-of-the-art mitigation technologies are critically evaluated to identify best practices and existing gaps in safety management. A
Jain, Gaurav, Premlal, P, Pathak, Rahul, Gore, Pandurang
Conceptual Framework for Real-Time Battery Health Estimation in Automotive Digital Twins Using Reinforcement Learning2026-26-06581/16/2026
The explosive growth of electric vehicles (EVs) calls forth the need for smart battery management systems that can perform health monitoring and predictive diagnostics in real-time. The conventional battery modelling methods mostly do not cover the complicated, dynamic behaviors coming from different usage patterns. The study outlines a structure that would use Reinforcement Learning (RL)-based AI agent as a part of the Battery Electrical Analogy (BEA) simulation platform. With the help of the AI agent, different health parameters such as State of Health (SOH), State of Charge (SOC), and the signs of early thermal runaway can be predicted in real-time. The suggested design takes advantage of the simulation-based approach to have the agent learn and utilizes a decentralized cloud architecture suitable for scaling and reducing the response time. The RL agent performs an essential role in the process by tagging along with the continuous learning and the adjustment of the battery
Pardeshi, Rutuja Rahul, Kondhare, Manish, Sasi Kiran, Talabhaktula
Preventing Thermal Run-Away using Shape Memory Alloy2026-26-00091/16/2026
The present disclosure is about combating Thermal runaway in Electric, Plug-in Hybrids and mild hybrid vehicles. This paper comprises of high-Voltage Battery pack containing Battery cells electrically coupled with Shape Memory Alloy along with Busbars. These connectors (Shape Memory Alloy) are programmed to operate in two states: First to electrically connect the cells with the busbars, second to disconnect the individual cells from electric connection beyond the threshold temperature. This mechanism enables the Battery cells to rapidly prevent the Battery from the Thermal runaway event which is caused from the cell level ensuring the Battery safety mechanically. Additionally, the Battery pack includes the cell monitoring system and Battery Monitoring System to enhance the above invention with regards to the safety of the vehicle. This configuration is implementable and retrofittable into existing battery systems, offering a robust solution to the challenges posed by prolonged vehicle
Reginald, Rini, Rout, Saswat, VENKATESH, Muthukrishnan, Chauhan, Ashish Jitendra, Selvaraj, Elayanila
Optimization and Evaluation of Thermal Interface Material Thickness and Distribution Patterns for Improved Heat Transfer in Liquid-Cooled Battery Pack2026-26-04321/16/2026
Battery Thermal Management Systems (BTMS) play a critical role in ensuring the longevity, safety, and efficient operation of lithium-ion battery packs. These systems are designed to better dissipate the heat generated by the cells during vehicle operation, thereby maintaining a uniform temperature distribution across the battery modules, preventing overheating and mitigating the chances of thermal runaway. However, one of the primary challenges in BTMS design lies in achieving effective thermal contact between the battery cells and the cooling plate. Non-uniform or excessive application of Thermal Interface Materials (TIMs) without ensuring robustness and uniformity can increase interfacial thermal resistance, leading to significant temperature variations across the battery modules, which may trigger power limitations via the Battery Management System (BMS) and these thermal changes can cause inefficient cooling, ultimately affecting battery performance and lifespan. In this paper, a
K, Mathankumar, Jahagirdar, Manasi, Kumbhar, Makarand Shivaji
State of Health Estimation in Lithium-Ion Batteries: Methods, Comparisons, and Future Directions2026-26-02081/16/2026
As the world is moving towards electric vehicles, we are observing a wide use of Lithium-Ion batteries in modern transportation. Lithium-Ion Batteries offer several advantages over conventional battery systems, including higher energy density that is energy stored per unit mass, longer Cycle Life, faster Charging rates, low Self-Discharge, lighter weight, and ease of maintenance as the memory effect present in other batteries is absent. However, despite these advantages, the system faces significant technical challenges arising from inaccurate battery State of Health (SOH) estimation techniques. These inaccuracies can lead to unexpected vehicle failures and a degraded end-user experience, especially due to incorrect “distance to empty” predictions. In this paper, different SOH estimation techniques are reviewed and compared in detail. The SOH estimation approaches are broadly classified into three main categories: Model based estimation techniques, data driven estimation techniques
Patel, Parvez, Bhagat, Ayush
Kinetic Modeling and Adaptive Time Stepping for Battery Thermal Runaway Propagation14-15-01-00031/12/2026
0D, quasi-3D, and 3D chemistry solvers with varying degrees of complexity are developed to predict the thermal runaway propagation in battery cells. The 0D solver assumes the system as homogeneous and closed. The quasi-3D solver assumes the system as homogeneous on the selection level and the 3D solver accounts all spatial inhomogeneities in the temperature and composition. Both the quasi-3D and 3D solvers are fully integrated into a computational fluid dynamic (CFD) solver and capable of predicting thermal runaway in multiple battery cells with cell-specific kinetic reaction model. As the modeling complexity increases with each solver, respectively, the accuracy and the simulation time increases. With the large amount of heat and rapid transitions from the onset of thermal runaway, the CFD solvers usually encounter difficulties in predicting the solution accurately and in extreme heat release cases the solver may diverge. A chemical time scale based adaptive time stepping is developed
Chittipotula, Thirumalesha
Constraint Enforcement of a Lithium-Ion Battery Pack Safety-Critical System for Electric Hybrid Vehicles2025-36-016012/18/2025
System robustness and performance are essential considerations in controller design to ensure reference tracking, disturbance rejection, and resilience to modeling uncertainties. However, guaranteeing that the system operates within safe bounds becomes a priority in safety-critical applications, even if performance must be compromised temporarily. One prominent example is the thermal management of lithium-ion battery packs, where temperature must be strictly controlled to prevent degradation and avoid hazardous thermal runaway events. In these systems, temperature constraints must consistently be enforced, regardless of external disturbances or control errors. Traditional strategies, such as Model Predictive Control (MPC), can explicitly handle such constraints but often require solving high-dimensional optimization problems, making real-time implementation computationally demanding. To overcome these limitations, this study investigates the use of a Constraint Enforcement strategy to
Ebner, Eric Rossini, Fernandes, Lucas Pasqual, Leal, Gustavo Nobre, Neto, Cyro Albuquerque, Leonardi, Fabrizio
Research on Thermal Runaway Triggering Methods for Non-Rechargeable Lithium Battery in Civil Aircraft2025-99-040512/10/2025
In aviation industry, compared to traditional batteries (lead-acid and nickel-cadmium batteries), non-rechargeable lithium batteries are usually the primary choice as independent backup power sources for emergency equipment (such as Emergency Locator Transmitter and Underwater Locator Beacon) due to excellent performance, weight/volume advantages and relatively long inspection/maintenance intervals. However, considering higher energy density and more active chemical characteristics, lithium batteries unique failure modes require special consideration in safety analysis. Among these failure modes, thermal runaway is one of the most severe failure modes of non-rechargeable lithium batteries, potentially leading to serious impact such as flame, explosion, and release of toxic and harmful gases/liquid. Therefore, it is necessary to demonstrate the containment of thermal runaway of non-rechargeable lithium batteries through equipment-level testing, and do aircraft-level safety analysis to
Zhang, Xiaoyu, Zheng, Jian, Yang, Dianliang, Sheng, Jiaqian
TOC99-07-06-0TOC12/2/2025
TOC
Tobolski, Sue
Experts agree on need for large-scale fire testing of battery energy storage systems25AUTP12_1612/1/2025
A panel of four battery testing experts from different fields agreed that large scale fire testing, as called for in a proposed update to testing standard UL 9540A, could help address confusion among consumers, battery companies and insurers. Moderated by LaTanya Schwalb, principal engineer for energy and industrial automation at UL Solutions, the panel discussion held at the Battery Show North America underscored the need for a current standard and for standards to adapt more quickly to new battery chemistries and technologies.
Clonts, Chris
Electrode-Level Modeling of Thermal Decomposition Reactions as a Foundation for Multiscale Thermal Runaway Analysis in Lithium-Ion Batteries2025-01-052311/25/2025
Thermal runaway in lithium-ion batteries represents a critical safety challenge, particularly in high-voltage battery systems used in electric vehicles and stationary energy storage. A comprehensive understanding of the multi-scale processes that initiate and propagate thermal runaway is essential for the development of effective safety measures and design strategies. This study provides a structured theoretical overview of the thermal runaway phenomenon across four hierarchical levels: electrode, single cell, module, and high-voltage battery system. At the electrode level, thermal runaway initiation is linked to electrochemical and chemical degradation mechanisms such as solid electrolyte interphase decomposition, separator breakdown, and internal short circuits. These processes lead to highly exothermic reactions that, at the cell scale, can result in rapid temperature increases, gas generation, and overpressure. On the module and system levels, thermal runaway can propagate through
Ceylan, Deniz, Kulzer, André Casal, Winterholler, Nina, Weinmann, Johannes, Schiek, Werner
Current Research Progress and Future Perspectives of Early Fire Prediction Modeling for Electric Vehicles14-15-01-000111/21/2025
With the wide application of electric vehicles (EVs) around the world, the increase in battery pack energy density and the growing complexity of electrical systems have gradually heightened the risk of vehicle fires. Therefore, achieving efficient and timely fire risk prediction is essential to minimize the probability of fires in EVs. However, the development of EV prediction models requires multidisciplinary integration to address complex safety challenges. This article provides a detailed discussion on the mechanisms and combustion characteristics of EV fires, followed by an investigation into the high-risk factors that trigger such fires. Based on the above content, this article conducts an in-depth analysis of the characteristics of different models for high-risk factors such as batteries, electrical systems, and collision damage, offering insights to bridge the gap between different disciplines. Finally, it explores the future development direction of predictive models for EVs
Shao, Yuyang, Cong, Beihua, Jianghong, Liu
Investigation on Flow Pattern Architecture Design on Thermal Plate for Battery Electric Vehicles2025-28-040610/30/2025
Liquid cooling systems are a widely used method for cooling lithium-ion batteries in modern electric vehicles. Battery thermal plate (BTP) is a key component of the liquid-cooled thermal management system, which regulates battery temperature to prevent thermal runaway and fire accidents. Designing an energy efficient flow pattern with uniform velocity and temperature distribution is a major challenge for the BTP. In this paper, the effect of flow patterns in cooling performance of the BTP is examined. Battery temperature can be efficiently controlled by varying direction, number of flow channels and structure of the BTP. Complex flow pattern networks are modeled and compared based on the computational fluid dynamics results. The channel flow resistance, pressure drop, and temperature distribution are key parameters which are evaluated for varying mass flow rate conditions. From this study, the flow pattern which satisfies the temperature requirement and has 10% less pumping power
K, Muthukrishnan, S, Saikrishna, K, Keshavbalaje, Gutte, Ashish
Thermal Management in Electrified Transportation: A Comparative Study of Different Powertrain Technologies2025-28-041210/30/2025
The transition towards sustainable transportation necessitates the development of advanced thermal management systems (TMS) for electric vehicles (EVs), hybrid electric vehicles (HEVs), hydrogen fuel cell vehicles (FCVs), and hydrogen internal combustion engine vehicles (HICEVs). Effective thermal control is crucial for passenger comfort and the performance, longevity, and safety of critical vehicle components. This paper presents a rigorous and comparative analysis of TMS strategies across these diverse powertrain technologies. It systematically examines the unique thermal challenges associated with each subsystem, including cabin HVAC, battery packs, fuel cell stacks, traction motors, and power electronics. For cabin HVAC, the paper explores methods for minimizing energy consumption while maintaining thermal comfort, considering factors such as ambient temperature, humidity, and occupant load. The critical importance of battery thermal management is emphasized, with a focus on
K, Neelima, K, Anisha, Ch, Kavya, C, Somasundar, Satyam, Satyam, P, Geetha
Items per page:
1 – 50 of 202