Failure and hazard characterisation of high-power lithium-ion cells via coupling accelerating rate calorimetry with in-line mass spectrometry, statistical and post-mortem analyses

Lithium-ion battery safety continues to be an obstacle for electric vehicles and electrified aerospace. Cell failure must be studied in order to engineer improved cells, battery packs and management systems. In this work, the thermal runaway of commercially available, high-power cells is studied, to understand the optimal areas to develop mitigation strategies. Accelerating rate calorimetry is coupled with mass spectrometry to examine self-heating and the corresponding evolution of gases. A statistical analysis of cell failure is then conducted, com-bined with post-mortem examinations. The methodology forms a robust assessment of cell failure, including the expected worst-and best-cases, and the associated real-world hazards. Cells produce a highly flammable, toxic gas mixture which varies over the course of self-heating. Failure also produces particulate matter which poses a severe health hazard. Critically, the onset of self-heating is detectable more than a day in advance of full thermal runaway. Likewise, voltage drops and leaks are detectable prior to venting, highlighting the potential for highly effective early onset detection. Furthermore, the behaviour of the cap during thermal runaway indicates that ejection of material likely reduces the chance of thermal runaway propagation to neighbouring cells. These findings also emphasise that research must be conducted safely.

Automated summary

Lithium-ion battery safety is crucial for electric vehicles and electrified aerospace. This study examines the thermal runaway of high-power cells and identifies areas for improvement. The research analyzes self-heating and gas evolution using calorimetry and mass spectrometry. Statistical analysis and post-mortem examinations provide a comprehensive assessment of cell failure, highlighting the flammable gas mixture and health hazards. Early detection of self-heating and voltage drops, as well as material ejection during thermal runaway, show potential for effective mitigation strategies.