Lithium-Ion Abusive Test at Megawatt scale

Abstract:
Lithium-ion batteries are at the core of electric transportation, powering everything from cars to buses and trucks, thanks to their high energy density and ability to deliver high levels of power at continuous level. These performances meet the growing demands of increasingly powerful and high-voltage systems (e.g., 1500 V). However, safety concerns, particularly fire risks, remain a major challenge. While thermal runaway mechanisms are well studied, electrical failures responsible for nearly 40% of lithium battery fires are less understood and studied. In particular, general external short circuits, which bypass external protections, pose a critical risk. This study addresses this gap by conducting large-scale abusive short-circuit tests (400 V, 7000 A) on Nickel Manganese Cobalt (NMC) cathode type automotive cells. We evaluate the system-level response to this extreme electrical fault, providing insights into failure mechanisms and breaking capacity limits of the cell’s integrated components. Our results, obtained in collaboration with Schneider Electric at the FLab Volta, offer crucial data to enhance battery safety standards and improve risk mitigation strategies in real-world applications.