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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↗

NASA NTRSDate not supplied

Comparative Analysis of Thermal Runaway Heat Output as a Function of Trigger Mechanism and Cell Format

High demand for energy storage systems across many fields drives the need for safe and reliable Li-ion batteries. In order to assess the risk of using such batteries in various applications, many types of abuse tests have been developed to push battery cells to their limits and learn how they fail. In this work, internal short circuit (ISC) tests, nail penetration tests, and thermal tests were used to trigger thermal runaway in D-cell, 18650, and 21700 Li-ion cells. High-speed radiography was used to gain insight to the propagation of thermal runaway throughout the cell, while calorimetric and thermal data were recorded in real time. Post-test disassembly of the calorimeter allowed for any mass ejected from the cell to be analyzed and the distribution of mass through the calorimeter to be determined. The impact of cell geometry and trigger mechanism on post-test mass distribution, thermal runaway propagation and internal cell temperature are discussed.

Lithium-ion battery; thermal runaway; calorimetry;↗

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↗

NASA NTRS1971

Runaway stars in the Gum Nebula

It is proposed that the two pulsars PSR 0833-45 (the Vela pulsar) and MP 0835 are runaways from a common binary system originally located in the B association around gamma Velorum. Arguments are presented for a simple model of the Gum nebula in which two distinct ionized regions are present. The first consists of the Stromgren spheres of gamma Velorum and zeta Puppis, while the second is a larger, more filamentary region ionized by the supernova explosion associated with PSR 0833-45. Using this model and the available dispersion measures, the distances to the two pulsars were estimated and found to be compatible with a runaway origin. The position angle of the rotation axis of PSR 0833-45 is also compatible with this origin. The masses of the parent stars of the two pulsars can be deduced from the runaway star dynamics and an assumed age for MP 0835. It is concluded that the masses were in excess of 10 solar masses. The dynamically-determined parent star masses are in agreement with the values expected for evolved members of the B association around gamma Velorum.

Got, J. R., III↗

NASA NTRS1983

A search for X-rays from runaway stars

Enhanced X-ray emission from an early-type runaway star would be direct evidence for the presence of a collapsed companion, and thus for its origin as the result of a supernova explosion in a massive binary. To test this idea, measurements of X-ray fluxes in the 0.5-3 keV energy range from nine O and B type runaway stars were made with the Einstein Observatory. In each case, the X-ray luminosity observed does not exceed that expected from a normal OB star. Therefore we conclude that, if the runaway stars have collapsed companions, the separations of the components must be much greater than those in normal OB binaries.

Kumar, C. K.↗

NASA NTRS1992

Venus: The case for a wet origin and a runaway greenhouse

To one interested in atmospheric evolution, the most intriguing aspect of our neighboring planet Venus is its lack of water. Measurements made by Pioneer Venus and by Several Venera spacecraft indicate that the present water abundance in Venus' lower atmosphere is of the order of 20 to 200 ppmv, or 3 x 10( exp -6) to 3 x 10 (exp -5) of the amount of water in Earth's oceans. The exact depletion factor is uncertain, in part because of an unexplained vertical gradient in H2O concentration in the lowest 10 km of the venusian atmosphere, but the general scarcity of water is well established. The interesting question, then, is: Was venus deficient in water when it formed and, if not, where did its water go? The conclusion that Venus was originally wet is consistent with its large endowment of other volatiles and with the enhanced D/H ratio in the present atmosphere. The most likely mechanism by which Venus could have lost its water is by the development of a runaway or moist greenhouse atmosphere followed by photodissociation of water vapor and escape of hydrogen to space. Climate model calculations that neglect cloud albedo feedback predict the existence of two critical transitions in atmospheric behavior at high solar fluxes: (1) at a solar flux of approximately 1.1 times the value at Earth's orbit, S(o), the abundance of stratospheric water vapor increases dramatically, permitting rapid escape of hydrogen to space (termed a moist greenhouse) and (2) at a solar flux of approximately 1.4 S(o), the oceans vaporize entirely, creating a true runaway greenhouse. If cloudiness increases at high surface temperatures, as seems likely, and if the dominant effect of clouds is to cool the planet by reflecting incident solar radiation, the actual solar flux required to create moist or runaway conditions would be higher than the values quoted above. Early in solar system history, solar luminosity was about 25 percent to 30 percent less than today, putting the flux at Venus' orbit in the range of 1.34 S(o) to 1.43 S(o). Thus, it is possible that Venus had liquid water on its surface for several hundred million years following its formation. Paradoxically, this might have facilitated water loss by sequestering atmospheric CO2 in carbonate rocks and by providing an effective medium for surface oxidation.

Kasting, J. F.↗

NASA NTRS1994

Thermonuclear runaways in nova outbursts. 2: Effect of strong, instantaneous, local fluctuations

In an attempt to understand the manner in which nova outbursts are initiated on the surface of a white dwarf, we investigate the effects fluctuations have on the evolution of a thermonuclear runaway. Fluctuations in temperature density, or the composition of material in the burning shell may arise due to the chaotic flow field generated by convection when it occurs, or by the accretion process itself. With the aid of two-dimensional reactive flow calculations, we consider cases where a strong fluctutation in temperature arises during the early, quiescent accretion phase or during the later, more dynamic, explosion phase. In all cases we find that an instantaneous, local temperature fluctuation causes the affected material to become Rayleigh-Taylor unstable. The rapid rise and subsequent expansion of matter immediately cools the hot blob, which prevents the lateral propagation of burning. This suggests that local temperature fluctuations do not play a significant role in directly initiating the runaway, especially during the early stages. However, they may provide an efficient mechanism of mixing core material into the envelope (thereby pre-enriching the fuel for subsequent episodes of explosive hydrogen burning) and of mixing substantial amounts of the radioactive nucleus N-13 into the surface layers, making novae potential gamma-ray sources. This suggests that it is the global not the local, evolution of the core-envelope interface to high temperatures which dominates the development of the runaway. We also present a possible new scenario for the initiation of nova outbursts based on our results.

Shankar, Anurag↗

NASA NTRS1996

Effects of Spatial Gradients on Electron Runaway Acceleration

The runaway process is known to accelerate electrons in many laboratory plasmas and has been suggested as an acceleration mechanism in some astrophysical plasmas, including solar flares. Current calculations of the electron velocity distributions resulting from the runaway process are greatly restricted because they impose spatial homogeneity on the distribution. We have computed runaway distributions which include consistent development of spatial gradients in the energetic tail. Our solution for the electron velocity distribution is presented as a function of distance along a finite length acceleration region, and is compared with the equivalent distribution for the infinitely long homogenous system (i.e., no spatial gradients), as considered in the existing literature. All these results are for the weak field regime. We also discuss the severe restrictiveness of this weak field assumption.

MacNeice, Peter↗

NASA NTRS2004

An Impact Triggered Runaway Greenhouse on Mars

When a planet is in radiative equilibrium, the incoming solar flux balances the outgoing longwave flux. If something were to perturb the system slightly, say the incoming solar flux increased, the planet would respond by radiating at a higher surface temperature. Since any radiation that comes in must go out, if the incoming is increased, the outgoing must also increase, and this increase manifests itself as a warmer equilibrium temperature. The increase in solar flux would correspond to an increase in temperature, which would increase the amount of water vapor in the atmosphere due to increased evaporation. Since water vapor is a greenhouse gas, it would absorb more radiation in the atmosphere leading to a yet warmer equilibrium temperature. The planet would reach radiative equilibrium at this new temperature. There exists a point, however, past which this positive feedback leads to a "runaway" situation. In this case, the planet does not simply evaporate a little more water and eventually come to a slightly higher equilibrium temperature. Instead, the planet keeps evaporating more and more water until all of the planet's available liquid and solid water is in the atmosphere. The reason for this is generally understood. If the planet's temperature increases, evaporation of water increases, and the absorption of radiation increases. This increases the temperature and the feedback continues until all water is in the atmosphere. The resulting equilibrium temperature is very high, much higher than the equilibrium temperature of a point with slightly lower solar flux. One can picture that as solar flux increases, planetary temperature also increases until the runaway point where temperature suddenly "jumps" to a higher value, in response to all the available water now residing in the atmosphere. This new equilibrium is called a "runaway greenhouse" and it has been theorized that this is what happened to the planet Venus, where the surface temperature is more than 700 K (427 C).

Segura, T. L.↗

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↗

DOE OSTI2022

Quantitative spatiotemporal mapping of thermal runaway propagation rates in lithium-ion cells using cross-correlated Gabor filtering

Abuse testing of lithium-ion batteries is widely performed in order to develop new safety standards and strategies. However, testing methodologies are not standardised across the research community, especially with failure mechanisms being inherently difficult to reproduce. High-speed X-ray radiography is proven to be a valuable tool to capture events occurring during cell failure, but the observations made remain largely qualitative. We have therefore developed a robust image processing toolbox that can quantify, for the first time, the rate of propagation of battery failure mechanisms revealed by high-speed X-ray radiography. Using Gabor filter, the toolbox selectively tracks the electrode structure at the onset of failure. This facilitated the estimation of the displacement of electrodes undergoing abuse via nail penetration, and also the tracking of objects, such as the nail, as it propagates through a cell. Further, by cross-correlating the Gabor signals, we have produced practical, illustrative spatiotemporal maps of the failure events. From these, we can quantify the propagation rates of electrode displacement prior to the onset of thermal runaway. The highest recorded acceleration (≈514 mm s -2 ) was when a nail penetrated a cell radially (perpendicular to the electrodes) as opposed to axially (parallel to the electrodes). The initiation of thermal runaway was also resolved in combination with electrode displacement, which occurred at a lower acceleration (≈108 mm s -2 ). Our assistive toolbox can also be used to study other types of failure mechanisms, extracting otherwise unattainable kinetic data. Ultimately, this tool can be used to not only validate existing theoretical mechanical models, but also standardise battery failure testing procedures.

25 ENERGY STORAGE↗