Impact of Vibration Testing on Thermal Performance and Degradation of Modern Lithium-Ion Batteries

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Advancements in Vibration Testing: Effects on Thermal Performance and Degradation of Modern Batteries

Abstract: Lithium-ion cells are increasingly being utilized as central power storage systems in modern applications, including e-bikes, electric vehicles (EVs), satellites, and spacecraft, and they are subjected to significant and constant vibrations. This review investigates how these vibrations impact the mechanical, thermal, and electrical properties of batteries. Vibrations can lead to structural problems, such as the separation of electrodes and deformation of separators, which increase internal resistance and generate localized heat. Consequently, thermal management becomes more complex, battery aging accelerates, and safety risks, including short circuits and thermal runaways, arise. To address these challenges, more realistic testing protocols that consider the combined effects of vibrations, temperature, and mechanical stress are needed. Enhancing thermal management systems (TMSs) with advanced cooling techniques and materials, such as phase change solutions, can mitigate these issues. Furthermore, designing batteries with vibration-resistant materials and improved structural integrity is essential for enhancing durability. Additionally, vibrations significantly influence various degradation mechanisms, including dendrite formation, self-discharge, and lithium plating, all of which can diminish battery capacity and lifespan. Our current research builds on these insights by employing a multiscale physics-based modeling approach to examine how vibrations interact with thermal behavior and contribute to battery degradation. By integrating computational models with experimental data, we aim to establish strategies and tools to enhance the safety, reliability, and longevity of lithium-ion batteries in challenging environments.

1. Introduction

Lithium-ion batteries have become the leading energy storage technology across various applications, from consumer electronics to large-scale systems like EVs and renewable energy storage. They are favored for their high energy density, long cycle life, low self-discharge rates, and minimal maintenance needs compared to traditional rechargeable batteries. As demand for clean energy solutions rises, particularly in the UK’s ambition to achieve net-zero carbon emissions by 2050, the significance of battery energy storage technology becomes increasingly apparent. However, the rapid adoption of lithium-ion batteries presents challenges concerning their performance, safety, and durability, especially when exposed to harsh environmental conditions or mechanical and electrical stresses.

Real-world operating conditions expose batteries to fluctuating forces that gradually degrade their internal structure. This degradation can result in microfractures, electrode delamination, and separator deformation, leading to increased internal resistance and localized heating, which may compromise battery safety and performance. Traditional testing methods often fall short of capturing the full extent of vibration-induced degradation, highlighting the necessity for advanced testing protocols that integrate mechanical, thermal, and electrochemical stress factors.

1.1. Research Background

Lithium-ion batteries have gained widespread popularity due to their advantages over other types, including high energy densities and long cycle lives. As the demand for clean energy solutions grows, these batteries have become crucial in transforming industries, particularly in transportation and power generation. However, the performance and safety of lithium-ion batteries are highly sensitive to environmental conditions, mechanical stresses, and electrical abuse. Increased temperatures can accelerate degradation and lead to thermal runaway, a hazardous situation where the battery overheats and may catch fire or explode.

1.2. Research Hierarchy

Current gaps in lithium-ion battery testing pose significant risks for manufacturers and users alike. The network visualization illustrates the connections among research topics related to lithium-ion batteries, emphasizing the importance of studying how vibrations impact thermal behavior and degradation.

1.3. Research Motivation

Despite the growing importance of lithium-ion batteries, comprehensive knowledge about how vibrations affect their mechanical integrity, safety, and electrical efficiency is limited. Understanding how vibrations influence battery failure mechanisms is crucial for improving thermal management strategies, enhancing material resilience, and extending battery lifespan in demanding applications.

1.4. Problem Statement

This review aims to synthesize the existing research on the thermal behavior and degradation mechanisms of lithium-ion batteries, with a specific focus on the impact of vibrations, material behavior, and thermal properties on battery safety and performance. The study will explore simulation-based and hardware-based testing approaches utilized in the literature to model battery behavior under various stresses.

1.5. Research Questions

The following research questions arise for this review study:
– What critical factors influence lithium-ion batteries’ performance, thermal stability, and safety under vibrational conditions?
– To what extent do mechanical vibrations adversely impact the structural integrity, thermal behavior, and electrochemical performance of batteries?
– How do mechanical vibrations contribute to thermal runaway, electrochemical degradation, and long-term battery lifespan?
– Do vibrational forces compromise battery safety, operational range, and reliability in practical applications?

2. Recent Advancements in Battery Modeling and Vibration Testing

Lithium-ion batteries are crucial for energy storage in various applications, offering high energy density and long lifespans. However, real-world stresses can lead to structural damage, overheating, and accelerated degradation. Addressing these challenges requires advanced testing, improved designs, and modeling tools to enhance reliability.

2.1. Advanced Battery Modeling Techniques

Current battery models incorporate multiscale and multiphysics approaches that combine electrochemical, thermal, and mechanical factors to comprehensively review lithium-ion battery operation. The integration of machine learning and artificial intelligence into battery modeling enhances predictive capabilities further.

2.2. Battery Testing Procedures

COMSOL Multiphysics provides a range of methods and features to study vibrations in battery systems, integrating advanced simulation capabilities in solid mechanics, heat transfer, and electrochemistry.

2.3. Battery Performance and Safety

Core challenges in battery performance include improving energy density and cycle life. The review highlights that mechanical vibrations can significantly impact battery performance and safety, emphasizing the need for effective thermal management systems.

3. Vibrations and Their Effects on Thermal Behavior and Material Properties

Vibrations can lead to increased internal temperatures, raising internal resistance and creating a cycle of heat generation that further accelerates degradation. Prolonged exposure to vibrations can also result in thermal fatigue and material degradation.

4. Mechanisms of Degradation in Lithium-Ion Batteries Under Vibrations

The degradation mechanisms influenced by vibrations include loss of active lithium, electrode material degradation, solid-electrolyte interphase (SEI) layer growth, lithium plating, and electrolyte decomposition. Each of these mechanisms poses significant risks to battery safety and performance.

5. Effects of Vibrations on Thermal Runaway in Lithium-Ion Batteries

Mechanical vibrations contribute to thermal runaway by increasing internal resistance and generating excessive heat. The interplay between mechanical stresses and thermal behavior highlights the need for robust battery management systems and vibration-resistant designs.

6. Vibration-Induced Degradation in Lithium-Ion Batteries

Mechanical vibrations lead to structural failures, increasing internal resistance and accelerating key degradation processes. The review identifies critical degradation mechanisms that impact battery performance and safety.

7. Discussion

The findings indicate that thermal management, structural resilience, and environmental conditions are crucial for battery performance under vibrational stress. However, there is limited data on how combined stressors interact to impact battery performance.

8. Recommendations for Future Research

Future research should focus on real-world application testing, material-level diagnostics, and vibration-tolerant battery designs. Addressing the combined effects of thermal and mechanical stresses will be vital for optimizing battery safety and performance.

9. Conclusions

This review underscores the significant impact of vibrations on the performance and degradation of lithium-ion batteries, emphasizing the need for improved testing protocols and battery designs to enhance safety and longevity in demanding environments. By combining computational models with experimental data, this research aims to develop strategies to improve the safety, reliability, and lifespan of lithium-ion batteries.
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