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At least 37 records · Page 2
All sourcesNASA NTRSDOE OSTI
DOE OSTI2024

Counter Data Paucity through Adversarial Invariance Encoding: A Case Study on Modeling Battery Thermal Runaway

Lithium-ion batteries, widely used for their durability and high energy storage, face the risk of internal short circuits leading to catastrophic thermal runaway events. These events, triggered by external stimuli like mechanical loads, pose safety concerns in applications such as electric vehicles. Detecting and understanding thermal runaway events is crucial, but physics-driven models struggle to explain the non-linear evolution of battery temperature during these events, considering factors like material composition and state-of-charge. Due to the rarity of these events and the cost of data collection, we propose a deep learning (DL) model to predict battery temperature responses during thermal runaway. The challenge lies in the scarcity of data, making traditional DL models prone to overfitting and learning low-quality representations of the complex process.Our approach introduces a novel few-shot architecture that incorporates an adversarially governed invariant encoding process. This architecture aims to distill "invariant" relationships by addressing distributional shifts in data across various battery properties, facilitating the detection of thermal runaway events. Specifically, our results demonstrate that deep learning models conditioned on these "invariant" representations outperform state-of-the-art baselines, achieving a remarkable 96.8% performance improvement in terms of the popular metric MAPE. This framework presents a promising direction for enhancing battery safety modeling, particularly in the context of rare and complex events like thermal runaway. Our code and code and dataset used for the paper are public1.

Tabassum, Anika [ORNL] (ORCID:0000000254600955)↗
DOE OSTI2023

Sidewall Breach During Lithium-Ion Battery Thermal Runaway Triggered by Cell-to-Cell Propagation Visualized Using High-Speed X-Ray Imaging

With the rapid deployment of Li-ion batteries (LiBs) in a range of applications, it is crucial to ensure their safe operation. Therefore, it is necessary to investigate the rapid thermal runaway failure that LiBs can undergo if improperly operated or subjected to abuse scenarios so that hazardous events can be avoided or mitigated. Sidewall breaches or ruptures of LiBs during thermal runaway are considered the most hazardous failure scenario, resulting in hot abrasive flare from the casing of the cell that can impinge on neighbouring cells and lead to the propagation of thermal runaway throughout a battery pack. Yet, the process leading up to the sidewall breach is not well understood due to the extreme difficulty in visualizing such a failure in commercially relevant cells. With the application of a newly developed chamber for remote-controlled abuse testing of batteries coupled with simultaneous X-ray imaging, we demonstrate here for the first time an in-situ visualization of a sidewall breach. By further applying spatiotemporal mapping techniques, the internal thermal runaway events leading up to the sidewall breach can be analyzed in detail. Subsequently, the speed of the electrode layer delamination could be calculated to a speed of 0.6 m/s. These new insights bring more clarity regarding this phenomenon, that in turn can help battery designers improve battery safety.

battery safety↗
DOE OSTI2024

Wall heating by subcritical energetic electrons generated by the runaway electron avalanche source *

Abstract Subcritical energetic electrons (SEEs) produced by the runaway electron (RE) avalanche source at energies below the runaway threshold are found to be the primary contributor to surface heating of plasma-facing components (PFCs) during final loss events. This finding is supported by theoretical analysis, computational modeling with the Kinetic Orbit Runaway electrons Code (KORC), and qualitative agreement with DIII-D experimental observations. The avalanche source generates significantly more secondary electrons below the runaway threshold, which thermalize rapidly when well-confined. However, during a final loss event, the RE beam impacts the first wall, and SEEs are deconfined before they can thermalize. Additionally, because the energy deposition length decreases faster than energy, the deposited energy density, and thus the maximum PFC surface temperature change, is larger for SEEs than REs. KORC simulations employ an analytic first wall to model particle deconfinement onto a non-axisymmetric wall composed of individual tiles. PFC surface heating is calculated using a 1D model extended to include an energy-dependent deposition length scale. Simulations of DIII-D qualitatively agree with infrared (IR) imaging only when SEEs from the avalanche source are included. These results demonstrate that SEEs are the dominant contributor to PFC surface heating and indicate that the avalanche source plays a critical role in the PFC damage caused during final loss events. The prominence of SEEs also has important implications for interpreting IR imaging, one of the primary diagnostics for RE-wall interaction diagnosis, despite REs dominating the energy and current density. This result improves predictions of wall damage due to post-disruption REs to estimate material lifetime and design RE mitigation systems for ITER and future reactors.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2024

Dataset of mechanically induced thermal runaway measurement and severity level on Li-ion batteries

The deployment of Li-ion batteries covers a wide range of energy storage applications, from mobile phones, e-bikes, electric vehicles (EV) and stationary energy storage systems. However, safety issue such as thermal runaway is always one of the most important concerns to prevent Li-ion batteries from further market penetration. A standardized single-side indentation test protocol was developed to mechanically induce an internal short-circuit. The cell voltage, compressive load, indenter stroke, and temperature at the indentation point are measured in time series. The test data of each cell, along with cell parameters such as dimensions, mass, chemistry, state of charge (SOC), capacity, are integrated together to calculate a thermal runaway severity score from 0 to100. Complete data collection process including the original measured record, test method, severity score calculation scheme is presented in this article. The thermal runaway severity analysis and the more than 100 tested Li-ion battery records provide a good data source for further comparison and ranking of thermal runaway risks.

25 ENERGY STORAGE↗
DOE OSTI2026

Quantitative Analysis and Prediction of Thermal Runaway Metrics of High-Nickel Oxide Cathodes by Machine Learning Models

The pursuit of higher energy density in lithium-ion batteries has made high-nickel (Ni) layered oxides leading cathode candidates for next-generation electric vehicles. However, their poor thermal stability, particularly at Ni contents ≥ 90%, increases the risk of cathode-initiated thermal runaway. Furthermore, we present a data-driven framework combining linear and nonlinear machine learning models to predict key thermal runaway descriptors from a high-throughput differential scanning calorimetry database. With cathode composition and state of charge (SOC) as input features, the ensemble model accurately predicts peak temperature, heat release, and peak heat flow. SHAP analysis identifies Ni content and SOC as the dominant factors controlling thermal runaway temperature, while SOC primarily governs heat release and peak heat flow. Al, Mg, and Mn improve thermal stability by strengthening metal–oxygen bonding and delaying structural transformation, whereas B mainly reduces heat release through surface passivation. Validation with a new cathode composition confirms accurate prediction of SOC-dependent thermal runaway behavior and critical SOC.

25 ENERGY STORAGE↗
DOE OSTI2024

Simulation of DIII-D disruption with argon pellet injection and runaway electron beam

Abstract The next generation of large tokamaks, including ITER, will be equipped with a disruption mitigation system (DMS) that can be activated if a disruption is deemed to be imminent. Introducing impurities by pellet (large or shattered) or massive gas injection has been shown to be an effective mitigation mechanism on many tokamaks. The goal of the mitigation is to lessen the thermal and electromagnetic loads from the disruption without generating enough high-energy (runaway) electrons to damage the device. Variations of this mitigation process with impurity injection are presently being tested on many experiments. We have modeled one such impurity injection experiment on DIII-D using the M3D-C1 nonlinear 3D extended MHD code (Jardin et al 2012 Comput. Sci. Discovery 6 014002), The model includes an argon large pellet injection and ablation model, impurity ionization, recombination, and radiation, and runaway electron formation and subsequent evolution, including both Dreicer and avalanche sources. We obtain reasonable agreement with the experimental results for the timescale of the thermal and current quench and for the magnitude of the runaway electron plateau formed during the mitigation. This is the first 3D full MHD simulation with pellets and REs to simulate the disruption process and it also provides a partial validation of the M3D-C1 DMS model.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2024

Effects of Trigger Method on Fire Propagation during the Thermal Runaway Process in Li-ion Batteries

Lithium-ion batteries are prone to fire hazards due to the possibility of thermal runaway propagation. During battery product development and subsequent safety tests for design validation and safety certification, the thermal runaway onset is triggered by various test methods such as nail penetration, thermal ramp, or external short circuit. This failure initiation method affects the amount of heat contributions and the composition of gas generations. This study compares two such trigger methods, external heating and using a thermally-activated internal short circuit device (ISCD). The effects of the trigger method on total heat generation are experimentally investigated within 18650 cylindrical cells at single cell level as well as at multiple cell configuration level. The severity of failure was observed to be worse for cells with ISCDs at single cell level, whereas quite the opposite results were observed at multiple cell configuration level. A preliminary numerical analysis was performed to better understand the battery safety performance with respect to thermal runaway trigger methods and heat transfer conditions.

25 ENERGY STORAGE↗
DOE OSTI2022

Compressible battery foams to prevent cascading thermal runaway in Li-ion pouch batteries

Lithium-ion battery packs require thermal management to achieve optimum life and safety. This is becoming crucial for battery packs composed of high-energy-density cells. Pouch cells themselves achieve highest packaging efficiency but require additional structural support and thermal management when grouped into modules, especially under abusive conditions such as thermal runaway. Novel foam battery pads have demonstrated to cushion volume changes of pouch cells and are reengineered in this study to mitigate cell-to-cell thermal runaway propagation. The compressible pads are made of polyurethane foams incorporating flame-retardant additives or coatings, including intumescent and fire wall materials. Here their performances were evaluated by conducting nail penetration tests on modules composed of pouch cells at 100% state of charge (SOC), with the foams placed in between the cells. Experimental results show cascading thermal runaway was considerably delayed by polyurethane foams incorporating flame-retardant additives or coatings. Complete prevention of cascading failure was achieved with dense polyurethane foams with multilayered coatings of both fire wall and intumescent materials.

25 ENERGY STORAGE↗
DOE OSTI2024

Exploring thermal runaway propagation in Li-ion batteries through high-speed X-ray imaging and thermal analysis: Impact of cell chemistry and electrical connections

Battery safety design is important to consider from the individual Li-ion cell to the level of the macro-system. On the macro-level, failure in one single cell can lead to propagation of the thermal runaway and rapidly set a whole battery pack on fire. Factors that can impact the propagation outcome, such as cell model/chemistry and electrical connection are here investigated using a combination of measurements. Several abusive tests were conducted, combining two different cell models (Molicel P42A and LG M50, both 21700s) in series and parallel connections (16 tests per configuration). Overall, a propagation outcome of 56% was measured from the 32 conducted tests, a minimum temperature of 150 °C was required to initiate propagation, and the fastest propagation occurred in 123 s. Temperature measurements were higher in series connected cells, initiating the discussion of cell chemistry and internal resistance on this effect. The difference in current-flow during thermal runaway in series and parallel connections, and how this can affect the temperature evolution is further discussed. Spatio-temporal mapping of X-ray radiography allowed us to derive the speed of thermal runaway evolution inside the battery and has shown that series connected cells, in particular P42A, occur faster. It was further observed that deviant sidewall behaviors such as temperature-induced breaches and pressure-induced ruptures occurred in P42As only respective nail-penetrated cells only.

25 ENERGY STORAGE↗
DOE OSTI2026

Gas-driven short disconnection mitigates thermal runaway in Li-ion batteries under mechanical abuse

Mechanical abuse poses a critical safety risk to Li-ion batteries by inducing internal short circuits that initiate thermal runaway. Remarkably, voltage recovery frequently emerges during thermal runaway initiation, a phenomenon that conventional theories fail to explain. Here, our study develops a new multiphysics mechanism to explain voltage recovery, termed gas-driven short disconnection, whereby internal gas pressure mechanically disengages short-circuit contacts and causes the cell voltage to rebound. This mechanism incorporates gas generation and its structural impact on the short circuit. Real-time optical and thermal imaging and X-ray computed tomography reveal fluid-structure interaction between internal gas flow and adjacent shorting contacts. We establish a mechanistic framework linking gas-driven short disconnection to cell-level voltage and temperature responses, elucidating the extension–truncation pattern of voltage recovery. Furthermore, thermal regime maps show that a voltage recovery duration exceeding 5 s correlates with limited temperature rise below 150 °C, indicating that sustained short-circuit disconnection suppresses Joule heating. Additionally, a dimensionless criterion is deduced from scaling analysis for physical plausibility of gas-driven short disconnection in mechanically abused cells. This finding inspires smart venting control, which regulates gas release to maintain the internal pressure while dissipating gas enthalpy, thereby providing a device-level strategy for thermal runaway mitigation.

Gas-driven short disconnection↗
DOE OSTI2022

Lagrangian particle simulation of hydrogen pellets and SPI into runaway electron beam in ITER

Numerical studies of the ablation of pellets and shattered pellet injection (SPI) fragments into a runaway electron beam in ITER have been performed using a time-dependent pellet ablation code [Samulyak et al., Nucl. Fusion, 61(4), 046007 (2021)]. The code resolves detailed ablation physics near pellet fragments and large-scale expansion of ablated clouds. The study of a single-fragment ablation quantifies the influence of various factors, in particular, the impact ionization by runaway electrons and cross-field transport models, on the dynamics of ablated plasma and its penetration into the runaway beam. Simulations of SPI performed using different numbers of pellet fragments study the formation and evolution of the ablation clouds and their large-scale dynamics in ITER. In conclusion, the penetration depth of the ablation clouds is found to be of the order of 50 cm.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2023

Nonlinear saturation of whistler modes driven by runaway electrons

Runaway electrons exhibit kinetic instabilities with potentially beneficial consequences. The anomalous Doppler resonance between the electrons and whistler modes is a primary underlying mechanism. These instabilities require a first-principle nonlinear theoretical analysis, which would ultimately enable assessment of their impact on disruption mitigation and diagnostics, especially in ITER-relevant conditions. This paper presents recent progress in developing the required theoretical framework for isolated nonlinear resonances. By employing the generic bump-on-tail model, we predict the wave saturation levels in both near-threshold and strongly driven regimes. Remarkably, for the waves of interest, the parallel component of the wave vector dictates the parallel momentum of the resonant particles. This feature, together with the expected wave saturation level, provides a complete description of the resonance impact on the runaway electron distribution function. We show that the parametric dependence of the nonlinearly saturated mode provides a way to recover certain features of the runaway momentum distribution function.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2024

The battery failure databank: Insights from an open-access database of thermal runaway behaviors of Li-ion cells and a resource for benchmarking risks

The thermal response of Li-ion cells can greatly vary for identical cell designs tested under identical conditions, the distribution of which is costly to fully characterize experimentally. The open-source Battery Failure Databank presented here contains robust, high-quality data from hundreds of abuse tests spanning numerous commercial cell designs and testing conditions. Data was gathered using a fractional thermal runaway calorimeter and contains the fractional breakdown of heat and mass that was ejected, as well as high-speed synchrotron radiography of the internal dynamic response of cells during thermal runaway. The distribution of thermal output, mass ejection, and internal response of commercial cells are compared for different abuse-test conditions, which when normalized on a per amp-hour basis show a strong positive correlation between heat output from cells, the fraction of mass ejected from the cells, their energy- and power-density. Ejected mass was shown to contain 10x more heat per gram than non-ejected mass. The causes of 'outlier' thermal and ejection responses i.e., extreme cases, are elucidated by high-speed radiography which showed how occurrences such as vent clogging can create more hazardous conditions. High-speed radiography also demonstrated how the time-resolved interplay of thermal runaway propagation and mass ejection influences the total heat generated.

25 ENERGY STORAGE↗
DOE OSTI2022

Runaway electron deconfinement in SPARC and DIII-D by a passive 3D coil

The operation of a 3D coil—passively driven by the current quench (CQ) loop voltage—for the deconfinement of runaway electrons (REs) is modeled for disruption scenarios in the SPARC and DIII-D tokamaks. Nonlinear magnetohydrodynamic (MHD) modeling is carried out with the NIMROD code including time-dependent magnetic field boundary conditions to simulate the effect of the coil. Further modeling in some cases uses the ASCOT5 code to calculate advection and diffusion coefficients for REs based on the NIMROD-calculated fields, and the DREAM code to compute the runaway evolution in the presence of these transport coefficients. Compared with similar modeling in Tinguely et al (2021 Nucl. Fusion 61 124003), considerably more conservative assumptions are made with the ASCOT5 results, zeroing low levels of transport, particularly in regions in which closed flux surfaces have reformed. Of three coil geometries considered in SPARC, only the n = 1 coil is found to have sufficient resonant components to suppress the runaway current growth. Without the new conservative transport assumptions, full suppression of the RE current is maintained when the thermal quench MHD is included in the simulation or when the RE current is limited to 250kA, but when transport in closed flux regions is fully suppressed, these scenarios allow RE beams on the order of 1–2 MA to appear. Additional modeling is performed to consider the effects of the close ideal wall. In DIII-D, the CQ is modeled for both limited and diverted equilibrium shapes. In the limited shape, the onset of stochasticity is found to be insensitive to the coil current amplitude and governed largely by the evolution of the safety-factor profile. In both devices, prediction of the q-profile evolution is seen to be critical to predicting the later time effects of the coil.

71 CLASSICAL AND QUANTUM MECHANICS, GENERAL PHYSIC↗
DOE OSTI2026

Utilizing the deuterium-tritium fusion resonance to diagnose thermal runaway in igniting plasmas

For high-efficiency inertial confinement fusion implosions, it is predicted that a burning hot spot will successfully encompass all surrounding fuel and then transition into a thermal runaway where the internal energy increase from fusion occurs on a timescale faster than the expansion of the fuel is able to quench the fusion chain reaction after ignition occurs. Observation of this dynamic phase transition would indicate distinct burn properties and indicate an implosion's robustness. A technique for diagnosing the presence of thermal runaway from measurements of nuclear reaction history is presented. The technique is based on taking the logarithmic derivative of the nuclear reaction history, called the 𝛼 curve, and allowing a mathematical decoupling of the mass, volume, and thermal reactivity in the fusion reaction rate equation. During thermal runaway, where the thermal temperature dominates the burn dynamics, a maximum in the 𝛼 curve is found where there is a maximum in the first derivative of the thermal fusion reactivity, an effect to the deuterium-tritium (DT) fusion cross-section resonance. This provides a distinct signature related to the fundamental nature of the DT fusion nuclear resonance and signifies the transition into the fusion thermal instability. Impacts of charged particle transport on the effect are also assessed and the analytical formulas are compared and found to be in agreement with radiation hydrodynamic codes.

high-energy-density plasmas↗
DOE OSTI2023

Mechanically induced thermal runaway severity analysis for Li-ion batteries

Thermal runaway is one of the most important safety concerns in the deployment of Li-ion batteries. For this study, we developed a standardized single-side indentation test protocol to induce an internal short-circuit. Cell voltage, temperature, and applied compressive force are monitored as a function of time. Each cell is given an observed hazard severity (OHS in five categories) modified from the EUCAR table. Meanwhile a calculated hazard severity (CHS) is obtained solely based on temperature and voltage curves. The calculation formula considers the cell temperature, rate of temperature increase, cell capacity, state of charge (SOC), voltage drop, and voltage drop rate. Each term is assigned with an appropriate weight to scale the calculated score from 0 to100. This method was applied to >100 Li-ion batteries with various SOCs and chemistries, and their OHS and CHS were displayed against SOC. The purpose is to provide battery designers, manufacturers, and end-users a clear comparison of thermal runaway severity of different batteries.

25 ENERGY STORAGE↗
DOE OSTI2024

A physics-constrained deep learning surrogate model of the runaway electron avalanche growth rate

A surrogate model of the runaway electron avalanche growth rate in a magnetic fusion plasma is developed. This is accomplished by employing a physics-informed neural network (PINN) to learn the parametric solution of the adjoint to the relativistic Fokker–Planck equation. The resulting PINN is able to evaluate the runaway probability function across a broad range of parameters in the absence of any synthetic or experimental data. This surrogate of the adjoint relativistic Fokker–Planck equation is then used to infer the avalanche growth rate as a function of the electric field, synchrotron radiation and effective charge. Predictions of the avalanche PINN are compared against first principle calculations of the avalanche growth rate with excellent agreement observed across a broad range of parameters.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2026

Collision operator for electron runaway in cold weakly ionised plasmas

In cold weakly ionised plasmas, the Dreicer generation mechanism can be non-diffusive as demonstrated in a recent study. By expanding the previous letter, we present the detailed description of a proper collision operator to precisely account for the non-diffusive electron kinetics. The operator appropriately combines the Fokker–Planck operator and Boltzmann operator where free-bound collision cross-sections are valid in the low-energy region. The proposed operator is envisaged to predict runaway electron generation in cold weakly ionised plasmas, particularly to design a runaway-free reactor tokamak start-up.

fusion plasma↗