As battery use surges, researchers turn to ultrasound to scan for internal defects faster and more affordably than X-rays.
As battery-related fires increase globally, a new method developed by researchers at Drexel University could help manufacturers detect defects before they become dangerous. Using ultrasound, the team has built a benchtop diagnostic tool that offers a quicker, low-cost alternative to X-ray scans for spotting internal issues in lithium-ion batteries.
The technique promises faster identification of structural flaws that could trigger overheating or thermal runaway, serious safety risks in batteries used in everything from electric vehicles to smartphones.Detecting trouble with soundThe Drexel team used scanning acoustic microscopy to send low-energy sound waves through commercial pouch cell batteries. As the waves passed through various materials, they changed speed. This shift revealed internal structural and mechanical features, without interrupting the battery’s function.“By observing how the sound wave has changed upon interacting with the sample, we can deduce a number of structural and mechanical features,” the researchers wrote.This approach can detect gas buildup, dry areas, internal cracks, and misaligned components. Gas is particularly important to identify, as it signals dry regions where cells may short-circuit during use.Current checks aren’t enoughBattery manufacturers currently rely on visual inspections, limited testing of sample cells, and X-rays to verify quality. But X-ray imaging is slow, expensive, and limited in what it can reveal.“While the vast majority of lithium-ion batteries today are high performing and safe, defects are bound to exist when thousands of cells are used within electric vehicles and there are millions of electric vehicles being produced every year,” said Dr. Wes Chang, lead researcher and assistant professor at Drexel.The growing demand for consumer electronics and electric transport has driven a surge in battery production.According to Consumer Affairs, individuals now use three to four battery-powered devices daily, twice as many as five years ago. This rapid growth leaves room for lower-quality cells to enter the market.Expanding tools for R&DUltrasound is not only a manufacturing solution but also helps research labs develop new battery chemistries. Chang’s team partnered with SES AI, a lithium metal battery startup, to test the tool in a real-world R&D setting. Engineers used the feedback to refine designs quickly.“The sensitivity of ultrasound makes it useful not just for detecting defects in manufacturing, but also for gauging how new battery chemistries fail,” the team noted.Alongside the physical tool, the group developed open-source software that controls the instrument and runs fast data analysis. “We hope that by lowering the barrier to entry, ultrasonic testing can become a routine part of battery research and development,” said Chang.He added, “Battery scientists want to build better batteries, not develop new tools. We provide a user interface that is easy-to-use with regular software updates.”The team plans to improve the system further to allow three-dimensional imaging of both electrodes and entire cells, making internal flaws even easier to spot.The study is published in the journal Electrochimica Acta.
Battery Fire Battery Safety Drexel University Lithium-Ion Batteries Ultrasound Imaging
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