Ultrasonic method identifies faulty batteries before their failure
In a groundbreaking development for the electric vehicle industry, researchers from Drexel University have adapted an ultrasound technique originally used in geophysics and biomedical sciences to diagnose battery issues. This innovative method, now being used to detect defects in batteries, has the potential to prevent malfunctions in electric vehicles and significantly improve battery safety and reliability [1][2].
The noninvasive ultrasound testing method offers rapid analysis of data, making it easier for engineers to make adjustments and corrections during the design and testing process. By sending low-energy sound waves through commercial pouch-cell batteries, this acoustic approach allows for real-time internal inspection without damaging the cells [1].
The technology, based on scanning acoustic microscopy, tracks changes in the speed and behavior of sound waves as they move through the battery. This reveals hidden issues such as cracks, delamination, trapped gas, and material imbalances that traditional visual or sample-based tests often miss [1][2].
Key advantages of this ultrasound testing approach include real-time monitoring while the battery is operating, providing insights into electrochemical and mechanical behaviors as they happen [1][2]. The method is also noninvasive and fast, making it suitable for both lab research and production line quality control in the electric vehicle industry [1].
Moreover, the compact and low-cost setup can fit on a standard workbench, and open-source software automates hardware control and rapid data analysis, reducing the need for specialized training or proprietary tools [1]. The technique also enhances safety by identifying manufacturing defects or internal damage early enough to reduce the risk of battery fires and failures during use [1][3].
The ultrasound technique is particularly effective at detecting gas, which can indicate dry areas that could cause a battery to fail. Chang, a member of the team, hopes that the ease of use of the ultrasound testing method will make it a routine part of battery research and development [3].
The ultrasound technique can potentially become a standard tool for measuring and diagnosing next-generation battery performance. The Drexel team collaborated with SES AI, a lithium metal battery startup company, to deploy the ultrasound testing platform at their research and development site [3].
Current safety and quality control processes for manufactured batteries rely heavily on visual inspection and performance testing of select battery cells after they come off the line. However, this new ultrasound technique offers a more comprehensive solution, capable of gauging how new battery chemistries fail in research and development labs [3].
The group plans to continue improving the technology to scan battery electrodes and produce more detailed three-dimensional images. As our reliance on batteries continues to grow—with individuals using three to four electronic devices powered by batteries each day, a number that has doubled in the last five years—the need for reliable and safe battery technology has never been more critical [3].
Thousands of cells are used within electric vehicles, and even a small design or manufacturing flaw that is missed can lead to a massive batch of defective batteries making their way into the market. By implementing this ultrasound testing method, manufacturers and researchers can spot problematic batteries before they malfunction, ultimately preventing costly and dangerous failures in electric vehicles [1][3].
The noninvasive ultrasound testing method, based on scanning acoustic microscopy and leveraged for battery inspection, integrates science in its development by tracking changes in the speed and behavior of sound waves, a technology drawn from geophysics and biomedical sciences (like science, technology). This technique, effective at detecting gas and capable of providing real-time monitoring during battery operation, also offers advantages in speed, cost, and ease of use, making it suitable for both research and production (technology).
