Design of a miniature flow cell for in situ x-ray imaging of redox flow batteries

Flow batteries represent a possible grid-scale energy storage solution, having many advantages such as scalability, separation of power and energy capabilities, and simple operation. However, they can suffer from degradation during operation and the characteristics of the felt electrodes are little understood in terms of wetting, compression and pressure drops. Presented here is the design of a miniature flow cell that allows the use of x-ray computed tomography (CT) to study carbon felt materials in situ and operando, in both lab-based and synchrotron CT. Through application of the bespoke cell it is possible to observe felt fibres, electrolyte and pore phases and therefore enables non-destructive characterisation of an array of microstructural parameters during the operation of flow batteries. Furthermore, we expect this design can be readily adapted to the study of other electrochemical systems

Tracking internal temperature and structural dynamics during nail penetration of lithium-ion cells

Mechanical abuse of lithium-ion batteries is widely used during testing to induce thermal runaway, characterize associated risks, and expose cell and module vulnerabilities. However, the repeatability of puncture or ‘nail penetration’ tests is a key issue as there is often a high degree of variability in the resulting thermal runaway process. In this work, the failure mechanisms of 18650 cells punctured at different locations and orientations are characterized with respect to their internal structural degradation, and both their internal and surface temperature, all of which are monitored in real time. The initiation and propagation of thermal runaway is visualized via high-speed synchrotron X-ray radiography at 2000 frames per second, and the surface and internal temperatures are recorded via infrared imaging and a thermocouple embedded in the tip of the penetrating nail, respectively. The influence of the nail, as well as how and where it penetrates the cell, on the initiation and propagation of thermal runaway is described and the suitability of this test method for representing in-field failures is discussed

4D analysis of the microstructural evolution of Si-based electrodes during lithiation: Time-lapse X-ray imaging and digital volume correlation

Silicon is a promising candidate to substitute or complement graphite as anode material in Li-ion batteries due, mainly, to its high energy density. However, the lithiation/delithiation processes of silicon particles are inherently related to drastic volume changes which, within a battery's physically constrained case, can induce significant deformation of the fundamental components of the battery that can eventually cause it to fail. In this work, we use non-destructive time-lapse X-ray imaging techniques to study the coupled electrochemo-mechanical phenomena in Li-ion batteries. We present X-ray computed tomography data acquired at different times during the first lithiation of custom-built silicon-lithium battery cells. Microstructural volume changes have been quantified using full 3D strain field measurements from digital volume correlation analysis. Furthermore, the extent of lithiation of silicon particles has been quantified in 3D from the grey-scale of the tomography images. Correlation of the volume expansion and grey-scale changes over the silicon-based electrode volume indicates that the process of lithiation is kinetically affected by the reaction at the Si/LixSi interface

Investigating lithium-ion battery materials during overcharge-induced thermal runaway: an operando and multi-scale X-ray CT study

Catastrophic failure of lithium-ion batteries occurs across multiple length scales and over very short time periods. A combination of high-speed operando tomography, thermal imaging and electrochemical measurements is used to probe the degradation mechanisms leading up to overcharge-induced thermal runaway of a LiCoO2 pouch cell, through its interrelated dynamic structural, thermal and electrical responses. Failure mechanisms across multiple length scales are explored using a post-mortem multi-scale tomography approach, revealing significant morphological and phase changes in the LiCoO2 electrode microstructure and location dependent degradation. This combined operando and multi-scale X-ray computed tomography (CT) technique is demonstrated as a comprehensive approach to understanding battery degradation and failure

X-ray imaging of failure and degradation mechanisms of lithium-ion batteries

Lithium-ion batteries are becoming increasingly energy and power dense, and are required to operate in demanding applications and under challenging conditions. Both safety and performance of lithium-ion batteries need to be improved to meet the needs of the current demand, and are inextricably linked to their microstructure and mechanical design. However, there is little understanding of the complex, multi-length scale, structural dynamics that occur inside cells during operation and failure. From the evolving particle microstructure during operation to the rapid breakdown of active materials during failure, the plethora of dynamic phenomena is not well understood. In this thesis, both ex-situ and operando X-ray imaging, and computed tomography, in combination with image-based modelling and quantification are used to characterise battery materials and components in 3D. Degradation mechanisms are investigated across multiple length-scales, from the electrode particle to the full cell architecture, and direct comparisons between materials in their fresh and failed states are made. Rapid structural evolution that occurs during operation and failure is captured using high-speed synchrotron X-ray imaging, and quantified by correlating sequential tomograms. Consistent degradation mechanisms that occur over fractions of a second are identified and are shown to contribute significantly towards uncontrolled and catastrophic failure, and previously unexplored interplay between the mechanical design of cells and their safety and performance is described. The experiments reported here assess the thermal and mechanical responses of cells to extreme operating and environmental conditions. The interaction between the dynamic architecture of active materials and the mechanical designs of commercial cells are revealed, highlighting the importance of the engineering design of commercial lithium-ion batteries and their efficacy to mitigate failure. These insights are expected to influence the future design of safer and more reliable lithium-ion batteries

Comparison of three-dimensional analysis and stereological techniques for quantifying lithium-ion battery electrode microstructures

Lithium-ion battery performance is intrinsically linked to electrode microstructure. Quantitative measurement of key structural parameters of lithium-ion battery electrode microstructures will enable optimization as well as motivate systematic numerical studies for the improvement of battery performance. With the rapid development of 3-D imaging techniques, quantitative assessment of 3-D microstructures from 2-D image sections by stereological methods appears outmoded; however, in spite of the proliferation of tomographic imaging techniques, it remains significantly easier to obtain two-dimensional (2-D) data sets. In this study, stereological prediction and three-dimensional (3-D) analysis techniques for quantitative assessment of key geometric parameters for characterizing battery electrode microstructures are examined and compared. Lithium-ion battery electrodes were imaged using synchrotron-based X-ray tomographic microscopy. For each electrode sample investigated, stereological analysis was performed on reconstructed 2-D image sections generated from tomographic imaging, whereas direct 3-D analysis was performed on reconstructed image volumes. The analysis showed that geometric parameter estimation using 2-D image sections is bound to be associated with ambiguity and that volume-based 3-D characterization of nonconvex, irregular and interconnected particles can be used to more accurately quantify spatially-dependent parameters, such as tortuosity and pore-phase connectivity

The Hydro-electro-thermal Performance of Air-cooled, Open-cathode Polymer Electrolyte Fuel Cells: Combined Localised Current Density, Temperature and Water Mapping

In situ diagnostic techniques provide a means of understanding the internal workings of fuel cells so that improved designs and operating regimes can be identified. Here, a novel metrology approach is reported that combines current and temperature mapping with water visualisation using neutron radiography. The approach enables a hydro-electro-thermal performance map to be generated that is applied to an air-cooled, open-cathode polymer electrolyte fuel cell. This type of fuel cell exhibits a particularly interesting coupled relationship between water, current and heat, as the air supply has the due role of cooling the stack as well as providing the cathode reactant feed via a single source. It is found that water predominantly accumulates under the cooling channels (thickness of 70-100 μm under the cooling channels and 5-25 μm in the active channels at 0.5 A cm−2), in a similar fashion to the lands in a closed-cathode design, but contrary to passive open-cathode systems. The relationship between current, temperature and water accumulation is complex and highly dependent on location within the cell. However, there is a general trend that higher currents and cooling limitations, especially above 0.7 A cm−2 and below 3.9 × 10−3 m3 s−1, leads to temperatures above 60 °C, which dehydrate the membrane (water thickness of 10-25 um) and the cell operates below 0.5 V

Nitrogen Blanketing and Hydrogen Starvation in Dead-Ended-Anode Polymer Electrolyte Fuel Cells Revealed by Hydro-Electro-Thermal Analysis

Dead-ended anode operation has a number of practical advantages that simplify system complexity and lower cost for polymer electrolyte fuel cells. However, dead-ended mode leads to performance loss over time which can only be reversed by performing intermittent purge events. This work applies a combined hydro-electro-thermal analysis to an air-cooled open-cathode fuel cell, presenting experimental functional maps of water distribution, current density and temperature. This approach has allowed the identification of a 'nitrogen blanketing' effect due to nitrogen cross-over from the cathode and a 'bypass' effect where a peripheral gap between the gasket and the GDL offers a hydrogen flow 'short circuit' to the border of the electrode. A consequence of high local current density at the margin of the electrode, and resulting high temperatures, may impact the lifetime of the cell in dead-end mode

In-operando high-speed tomography of lithium-ion batteries during thermal runaway

Prevention and mitigation of thermal runaway presents one of the greatest challenges for the safe operation of lithium-ion batteries. Here, we demonstrate for the first time the application of high-speed synchrotron X-ray computed tomography and radiography, in conjunction with thermal imaging, to track the evolution of internal structural damage and thermal behaviour during initiation and propagation of thermal runaway in lithium-ion batteries. This diagnostic approach is applied to commercial lithium-ion batteries (LG 18650 NMC cells), yielding insights into key degradation modes including gas-induced delamination, electrode layer collapse and propagation of structural degradation. It is envisaged that the use of these techniques will lead to major improvements in the design of Li-ion batteries and their safety features

Characterising thermal runaway within lithium-ion cells by inducing and monitoring internal short circuits

Lithium-ion batteries are being used in increasingly demanding applications where safety and reliability are of utmost importance. Thermal runaway presents the greatest safety hazard, and needs to be fully understood in order to progress towards safer cell and battery designs. Here, we demonstrate the application of an internal short circuiting device for controlled, on-demand, initiation of thermal runaway. Through its use, the location and timing of thermal runaway initiation is pre-determined, allowing analysis of the nucleation and propagation of failure within 18 650 cells through the use of high-speed X-ray imaging at 2000 frames per second. The cause of unfavourable occurrences such as sidewall rupture, cell bursting, and cell-to-cell propagation within modules is elucidated, and steps towards improved safety of 18 650 cells and batteries are discussed