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United States Advanced Battery Consortium Battery Abuse Testing Manual for Electric and Hybrid Vehicle Applications

Torres-Castro, Loraine T.; Lamb, Joshua H.

This report describes recommended abuse testing procedures for rechargeable energy storage systems (RESSs) for electric vehicles. This report serves as a revision to the USABC Electrical Energy Storage System Abuse Test Manual for Electric and Hybrid Electric Vehicle Applications (SAND99-0497).

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TYPE Other Report YEAR 2022
OSTIDOI

I.6.C Battery Safety Testing

Lamb, Joshua H.

Abuse tests are designed to determine the safe operating limits of HEV\PHEV energy storage devices. Testing is intended to achieve certain worst-case scenarios to yield quantitative data on cell\module\pack response, allowing for failure mode determination and guiding developers toward improved materials and designs. Standard abuse tests with defined start and end conditions are performed on all devices to provide comparison between technologies. New tests and protocols are developed and evaluated to more closely simulate real world failure conditions. While robust mechanical models for vehicles and vehicle components exist, there is a gap for mechanical modeling of EV batteries. The challenge with developing a mechanical model for a battery is the heterogeneous nature of the materials and components (polymers, metals, metal oxides, liquids).

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TYPE Other Report YEAR 2021
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Investigating the Role of Energy Density in Thermal Runaway of Lithium-Ion Batteries with Accelerating Rate Calorimetry

Journal of the Electrochemical Society

Lamb, Joshua H.; Torres-Castro, Loraine T.; Hewson, John C.; Shurtz, Randy S.; Preger, Yuliya P.

This work uses accelerating rate calorimetry to evaluate the impact of cell chemistry, state of charge, cell capacity, and ultimately cell energy density on the total energy release and peak heating rates observed during thermal runaway of Li-ion batteries. While the traditional focus has been using calorimetry to compare different chemistries in cells of similar sizes, this work seeks to better understand how applicable small cell data is to understand the thermal runaway behavior of large cells as well as determine if thermal runaway behaviors can be more generally tied to aspects of lithium-ion cells such as total stored energy and specific energy. We have found a strong linear correlation between the total enthalpy of the thermal runaway process and the stored energy of the cell, apparently independent of cell size and state of charge. We have also shown that peak heating rates and peak temperatures reached during thermal runaway events are more closely tied to specific energy, increasing exponentially in the case of peak heating rates.

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TYPE Journal Article YEAR 2021
ScopusOSTIDOI

Predicting cell-to-cell failure propagation and limits of propagation in lithium-ion cell stacks

Proceedings of the Combustion Institute

Kurzawski, Andrew K.; Torres-Castro, Loraine T.; Shurtz, Randy S.; Lamb, Joshua H.; Hewson, John C.

Thermal runaway of Li-ion batteries is a risk that is magnified when stacks of lithium-ion cells are used for large scale energy storage. When limits of propagation can be identified so that systems can be designed to prevent large scale cascading failure even if a failure does occur, these systems will be safer. The prediction of cell-to-cell failure propagation and the propagation limits in lithium-ion cell stacks were studied to better understand and identify safe designs. A thermal-runaway model was considered based on recent developments in thermochemical source terms. Propagating failure was characterized by temperatures above which calorimetry data is available. Results showed high temperature propagating failure predictions are too rapid unless an intra-particle diffusion limit is included, introducing a Damköhler number limiter into the rate expression. This new model form was evaluated against cell-to-cell failure propagation where the end cell of a stack is forced into thermal runaway through a nail-induced short circuit. Limits of propagation for this configuration are identified. Results showed cell-to-cell propagation predictions are consistent with measurements over a range of cell states of charge and with the introduction of metal plates between cells to add system heat capacity representative of structural members. This consistency extends from scenarios where propagation occurs through scenarios where propagation is prevented.

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TYPE Journal Article YEAR 2021
ScopusOSTIDOI

Evaluation of Multi-cell Failure Propagation

Lamb, Joshua H.; Torres-Castro, Loraine T.; Stanley, June S.; Grosso, Christopher G.; Gray, Lucas S.

Failure propagation testing is of increasing interest to the designers and end users of battery systems. One of the chief difficulties, however, is choosing an appropriate initiation method to perform the test. Single cell abuse testing is typically used to initiate thermal runaway but this can involve a large amount of additional energy injected into the system. It is assumed that this will have some impact on the behavior of a propagating thermal runaway event, but there is little data available as to how significant this would be. Further, it is ultimately difficult to develop viable propagation tests for compliance and public safety activities without better knowledge of how test methods will impact the results. This work looks at propagating battery failure with a variety of chemistries, formats, configurations and initiation methods to determine the level of significance of the chosen initiation method on the test results. We have ultimately found while there is some impact on the detailed results of propagation testing, in most cases other factors, particularly the energy density of the system play a much greater role in the likelihood of a propagation event consuming an entire battery. We have also provided some guidelines for test design to support best practices in testing.

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TYPE SAND Report YEAR 2020
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Passive Mitigation of Cascading Propagation in Multi-Cell Lithium Ion Batteries

Journal of the Electrochemical Society

Torres-Castro, Loraine T.; Kurzawski, Andrew K.; Hewson, John C.; Lamb, Joshua H.

The heat generated during a single cell failure within a high energy battery system can force adjacent cells into thermal runaway, creating a cascading propagation effect through the entire system. This work examines the response of modules of stacked pouch cells after thermal runaway is induced in a single cell. The prevention of cascading propagation is explored on cells with reduced states of charge and stacks with metal plates between cells. Reduced states of charge and metal plates both reduce the energy stored relative to the heat capacity, and the results show how cascading propagation may be slowed and mitigated as this varies. These propagation limits are correlated with the stored energy density. Results show significant delays between thermal runaway in adjacent cells, which are analyzed to determine intercell contact resistances and to assess how much heat energy is transmitted to cells before they undergo thermal runaway. A propagating failure of even a small pack may stretch over several minutes including delays as each cell is heated to the point of thermal runaway. This delay is described with two new parameters in the form of gap-crossing and cell-crossing time to grade the propensity of propagation from cell to cell.

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TYPE Journal Article YEAR 2020
ScopusOSTIDOI

From calorimetry measurements to furthering mechanistic understanding and control of thermal abuse in lithium-ion cells

Journal of the Electrochemical Society

Shurtz, Randy S.; Preger, Yuliya P.; Torres-Castro, Loraine T.; Lamb, Joshua H.; Hewson, John C.; Ferreira, Summer R.

Lithium-ion battery safety is prerequisite for applications from consumer electronics to grid energy storage. Cell and component-level calorimetry studies are central to safety evaluations. Qualitative empirical comparisons have been indispensable in understanding decomposition behavior. More systematic calorimetry studies along with more comprehensive measurements and reporting can lead to more quantitative mechanistic understanding. This mechanistic understanding can facilitate improved designs and predictions for scenarios that are difficult to access experimentally, such as system-level failures. Recommendations are made to improve usability of calorimetry results in mechanistic understanding. From our perspective, this path leads to a more mature science of battery safety.

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TYPE Journal Article YEAR 2019
ScopusOSTIDOI

Determination of battery stability with advanced diagnostics

Lamb, Joshua H.; Torres-Castro, Loraine T.; Orendorff, Christopher O.; Dufek, Eric J.; Walker, Lee K.; Ho, Chinh H.

Lithium ion batteries for use in battery electric vehicles (BEVs) has seen considerable expansion over the last several years. It is expected that market share and the total number of BEVs will continue to increase over coming years and that there will be changes in the environmental and use conditions for BEV batteries. Specifically aging of the batteries and exposure to an increased number of crash conditions presents a distinct possibility that batteries may be in an unknown state posing danger to the operator, emergency response personnel and other support personnel. The present work expands on earlier efforts to explore the ability to rapidly monitor using impedance spectroscopy techniques and characterize the state of different battery systems during both typical operations and under abusive conditions. The work has found that it is possible to detect key changes in performance for strings of up to four cells in both series and parallel configurations for both typical and abusive response. As a method the sensitivity for detecting change is enhanced for series configurations. For parallel configurations distinct changes are more difficult to ascertain, but under abusive conditions and for key frequencies it is feasible to use current rapid impedance techniques to identify change. The work has also found it feasible to use rapid impedance as an evaluation method for underload conditions, especially for series strings of cells.

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TYPE SAND Report YEAR 2017
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Next generation molten NaI batteries for grid scale energy storage

Journal of Power Sources

Small, Leo J.; Eccleston, Alexis; Lamb, Joshua H.; Read, Andrew C.; Robins, Matthew; Meaders, Thomas; Ingersoll, David I.; Clem, Paul G.; Bhavaraju, Sai; Spoerke, Erik D.

Robust, safe, and reliable grid-scale energy storage continues to be a priority for improved energy surety, expanded integration of renewable energy, and greater system agility required to meet modern dynamic and evolving electrical energy demands. We describe here a new sodium-based battery based on a molten sodium anode, a sodium iodide/aluminum chloride (NaI/AlCl3) cathode, and a high conductivity NaSICON (Na1+xZr2SixP3−xO12) ceramic separator. This NaI battery operates at intermediate temperatures (120–180 °C) and boasts an energy density of >150 Wh kg−1. The energy-dense NaI-AlCl3 ionic liquid catholyte avoids lifetime-limiting plating and intercalation reactions, and the use of earth-abundant elements minimizes materials costs and eliminates economic uncertainties associated with lithium metal. Moreover, the inherent safety of this system under internal mechanical failure is characterized by negligible heat or gas production and benign reaction products (Al, NaCl). Scalability in design is exemplified through evolution from 0.85 to 10 Ah (28 Wh) form factors, displaying lifetime average Coulombic efficiencies of 99.45% and energy efficiencies of 81.96% over dynamic testing lasting >3000 h. This demonstration promises a safe, cost-effective, and long-lifetime technology as an attractive candidate for grid scale storage.

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TYPE Journal Article YEAR 2017
ScopusOSTIDOI

Failure propagation in multi-cell lithium ion batteries

Journal of Power Sources

Lamb, Joshua H.; Orendorff, Christopher O.; Steele, Leigh A.; Spangler, Scott W.

Traditionally, safety and impact of failure concerns of lithium ion batteries have dealt with the field failure of single cells. However, large and complex battery systems require the consideration of how a single cell failure will impact the system as a whole. Initial failure that leads to the thermal runaway of other cells within the system creates a much more serious condition than the failure of a single cell. This work examines the behavior of small modules of cylindrical and stacked pouch cells after thermal runaway is induced in a single cell. Cylindrical cells are observed to be less prone to propagate owing to the limited contact between neighboring cells. The electrical connectivity is found to be impactful as the 10S1P cylindrical cell module did not show failure propagation through the module, while the 1S10P module had an energetic thermal runaway consuming the module minutes after the initiation failure trigger. Modules built using pouch cells conversely showed the impact of strong heat transfer between cells. In this case, a large surface area of the cells was in direct contact with its neighbors, allowing failure to propagate through the entire battery within 60-80 s for all configurations (parallel or series) tested.

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TYPE Journal Article YEAR 2015
ScopusOSTI

Studies on the thermal breakdown of common Li-ion battery electrolyte components

Journal of the Electrochemical Society

Lamb, Joshua H.; Orendorff, Christopher O.; Roth, E.P.; Langendorf, Jill L.

While much attention is paid to the impact of the active materials on the catastrophic failure of lithium ion batteries, much of the severity of a battery failure is also governed by the electrolytes used, which are typically flammable themselves and can decompose during battery failure. The use of LiPF6 salt can be problematic as well, not only catalyzing electrolyte decomposition, but also providing a mechanism for HF production. This work evaluates the safety performance of the common components ethylene carbonate (EC), diethyl carbonate (DEC), dimethyl carbonate (DMC), and ethyl methyl carbonate (EMC) in the context of the gasses produced during thermal decomposition, looking at both the quantity and composition of the vapor produced. EC and DEC were found to be the largest contributors to gas production, both producing upwards of 1.5 moles of gas/mole of electrolyte. DMC was found to be relatively stable, producing very little gas regardless of the presence of LiPF6. EMC was stable on its own, but the addition of LiPF6 catalyzed decomposition of the solvent. While gas analysis did not show evidence of significant quantities of any acutely toxic materials, the gasses themselves all contained enough flammable components to potentially ignite in air.

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TYPE Journal Article YEAR 2015
ScopusOSTIDOI

Determination of battery stability with advanced diagnostics

Lamb, Joshua H.; Orendorff, Christopher O.; Christophersen, Jon P.

The increasing demand of lithium ion batteries for vehicle electrification is changing the typical use conditions that batteries may see. Over time, batteries may develop defects that are difficult to detect with traditional measurements. It is also possible that batteries may be left in an unknown state after failure of the monitoring system, loss of communication, or a potentially damaging event (such as an auto accident). It is therefore useful to explore other monitoring and interrogation methods that can better determine the stability of a battery in an unknown state. This work explores the use of electrochemical impedance spectroscopy as a method to determine the stability of batteries by observing changes in the complex impedance measurement as the cell is exposed to abusive conditions. Very dramatic changes to the internal resistance were observed when single cells were exposed to abusive conditions, suggesting that even single frequency impedance measurements could be effective with single cells. However tests on three cell series and parallel strings yielded smaller changes, primarily to the charge transfer resistance, showing that complex impedance measurements are more appropriate as the system increases in complexity. A rapid impedance tool developed at Idaho National Laboratory was tested and compared to traditional potentiostat tools as well. This was shown to yield similar data to the traditional tools, providing a potential method for continuous monitoring of a battery system. It was observed, however, that shifts in the data are difficult to detect in very transient systems.

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TYPE SAND Report YEAR 2014
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Potential use of battery packs from NCAP tested vehicles

Lamb, Joshua H.; Orendorff, Christopher O.

Several large electric vehicle batteries available to the National Highway Traffic Safety Administration are candidates for use in future safety testing programs. The batteries, from vehicles subjected to NCAP crashworthiness testing, are considered potentially damaged due to the nature of testing their associated vehicles have been subjected to. Criteria for safe shipping to Sandia is discussed, as well as condition the batteries must be in to perform testing work. Also discussed are potential tests that could be performed under a variety of conditions. The ultimate value of potential testing performed on these cells will rest on the level of access available to the battery pack, i.e. external access only, access to the on board monitoring system/CAN port or internal electrical access to the battery. Greater access to the battery than external visual and temperature monitoring would likely require input from the battery manufacturer.

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TYPE SAND Report YEAR 2013
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153 Results
153 Results