4D insights into lithium-ion battery sidewall rupture during thermal runaway
Year: 2026
Type: article
Abstract: Thermal runaway (TR), characterized by rapid exothermic reactions, presents a serious safety risk in lithium-ion batteries (LiBs). External triggers such as high temperatures, mechanical abuse, or internal short circuits (ISCs) can initiate TR, often resulting in sidewall rupture, which may escalate to catastrophic battery pack failure. In this study, we developed and applied high-speed synchrotron imaging techniques to investigate sidewall rupture mechanisms in LiBs subjected to different triggering scenarios. Using in situ 4D tomographic imaging, we visualized the dynamic evolution of sidewall rupture with high spatial and temporal resolution. The results revealed distinct failure behaviors linked to each trigger, underscoring the complex and condition-specific nature of sidewall breach and battery failure. These insights highlight the critical importance of implementing tailored safety strategies across diverse applications. Our findings demonstrate the powerful potential of synchrotron high-speed tomography as a diagnostic tool for advanced safety testing and cell qualification.
Source: Cell Reports Physical Science
Institutions: European Synchrotron Radiation Facility, University College London, Fraunhofer Institute for High-Speed Dynamics, Ernst-Mach-Institut, Politecnico di Milano, The Faraday Institution, National Physical Laboratory, National Laboratory of the Rockies, National Aeronautics and Space Administration, Johnson Space Center, University of Oxford
Language: English
Subfield: Automotive Engineering
Field: Engineering
Domain: Physical Sciences
Open Access status: gold
Estimated APC paid: $5,620
OpenAlex ID: W7128031287