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From micro-explosions to full-scale fire: Predicting thermal runaway in ultra-high nickel lithium-ion batteries with layering effect

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  • Mehrotra, Ayushi
  • Berwal, Pragya
  • Oh, Juyoung
  • Lee, Yejun
  • Yoh, Jack J.

Abstract

Lithium-ion batteries (LIBs) are crucial for various applications but are susceptible to thermal runaway (TR), especially as energy densities increase. This study examines TR behavior in LIB components using multi-layer thermochemical analysis. Anode, cathode, and separator layers from 88 % nickel (NCA88) and 91 % nickel (NCA91) cathode-based LIBs were analyzed using Differential Scanning Calorimetry (DSC) under controlled heating rates of 10 °C/min, 15 °C/min, and 20 °C/min. A multi-layer micro-cell configuration was developed to assess layer-dependent thermal interactions. Results indicate that solid electrolyte interphase (SEI) degradation onset varies with both layering and heating rate, occurring as early as 68.9 °C (NCA88, 3-layer, 10 °C/min) and 69.2 °C (NCA91, 2-layer, 10 °C/min). In contrast, for a single-layer system, SEI degradation begins at 97.2 °C (NCA88) and 95.0 °C (NCA91) at 10 °C/min. Cathode degradation initiates between 202.3 °C and 246.6 °C, with peak degradation temperatures reaching 243.9 °C (NCA91, 3-layer, 20 °C/min). Increasing layers led to a broader thermal degradation range, with endset temperatures extending up to 276.8 °C (NCA91, 2-layer, 10 °C/min), indicating improved heat dissipation. These findings highlight the role of layer-wise thermal interactions in influencing TR progression, particularly for NCA91, which exhibits greater thermal stability over NCA88. The study validates a microscopic approach for predicting large-scale LIB failure by using interpolation techniques to estimate TR behaviors in multi-layer battery stacks. The results provide a foundation for enhancing LIB safety through optimized thermal management strategies.

Suggested Citation

  • Mehrotra, Ayushi & Berwal, Pragya & Oh, Juyoung & Lee, Yejun & Yoh, Jack J., 2025. "From micro-explosions to full-scale fire: Predicting thermal runaway in ultra-high nickel lithium-ion batteries with layering effect," Energy, Elsevier, vol. 320(C).
    • Handle: RePEc:eee:energy:v:320:y:2025:i:c:s0360544225011442
    DOI: 10.1016/j.energy.2025.135502
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    References listed on IDEAS

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    1. Wang, Yu & Ren, Dongsheng & Feng, Xuning & Wang, Li & Ouyang, Minggao, 2022. "Thermal runaway modeling of large format high-nickel/silicon-graphite lithium-ion batteries based on reaction sequence and kinetics," Applied Energy, Elsevier, vol. 306(PA).
    2. Kvasha, Andriy & Gutiérrez, César & Osa, Urtzi & de Meatza, Iratxe & Blazquez, J. Alberto & Macicior, Haritz & Urdampilleta, Idoia, 2018. "A comparative study of thermal runaway of commercial lithium ion cells," Energy, Elsevier, vol. 159(C), pages 547-557.
    3. Zhang, Wencan & Ouyang, Nan & Yin, Xiuxing & Li, Xingyao & Wu, Weixiong & Huang, Liansheng, 2022. "Data-driven early warning strategy for thermal runaway propagation in Lithium-ion battery modules with variable state of charge," Applied Energy, Elsevier, vol. 323(C).
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