Failure modes, safety concerns, testing protocol, and advancement in lithium-ion battery technology

Lithium-ion batteries (LIBs) play a pivotal role in electric vehicle (EV) technology due to their high energy density and efficiency. However, their vulnerability to thermal runaway, fire, and explosion remains a major barrier to widespread adoption. This study addresses the lack of integrated analysis by reviewing current research trends in LIBs, advancements in EV applications, common failure modes, safety concerns, testing protocols, and AI/ML-based safety enhancements. While previous studies have often treated these aspects separately, this paper consolidates critical issues such as overcharging, mechanical wear, separator degradation, lithium plating, and electrolyte breakdown, alongside safety testing standards like thermal, penetration, and crushing tests. It further explores emerging innovations including risk-free electrolyte chemistries, stabilized electrode interfaces, and phase change materials for thermal management. The novelty lies in its multidimensional approach, linking material degradation, diagnostics, and sustainability. The review concludes that integrating predictive AI models, improving material robustness, and adopting stringent safety protocols are essential to mitigating LIB risks and ensuring safer, more sustainable EV deployment.