A comparative study on mechanical-electrical-thermal characteristics and failure mechanism of LFP/NMC/LTO batteries under mechanical abuse

Understanding the failure behaviors and failure mechanisms of lithium-ion batteries under mechanical abuse is essential for numerical reconstruction of abuse scenarios for different types of cells. This study investigates the mechanical-electrical-thermal characteristics, components tensile properties and failure mechanisms of LiFePO₄ (LFP), Li(Ni_0.5Mn_0.3Co_0.2)O₂ (NMC), and Li₂TiO₃ (LTO) cells through indentation experiments, including ball intrusion, cylindrical intrusion, and out-of-plane compression modes at quasi-static loading rates. Additional ball intrusion experiments were conducted at varying loading rates. This study compares the effects of different material systems on battery performance under standardized mechanical abuse conditions. Post-test examinations analyze surface damage and internal component fracture morphology. Two distinct fracture modes were observed: ductile fracture and brittle fracture. The findings suggest that, under the same loading mode, LTO cells exhibit distinct failure behavior compared to NMC and LFP cells, attributed to differing material properties and resulting fracture modes during intrusion. Based on the analysis of the tensile results of the battery components, the cell fracture mode may be related to the tensile strength of the separator. The loading rate significantly impacts the mechanical-electrical-thermal performance of pouch cells, resulting in increased cell stiffness and shorter internal short circuit duration at higher loading speeds. However, the effect of loading rate is consistent across cells with different material systems.