I-Corps: Cell Failure Analysis of Lithium-ion Batteries

锂离子（Li-ion）电池的失效原因和机理对于提高混合动力汽车、军事和航空航天应用中使用的电池的可靠性至关重要。锂离子电池单元的失效分析是一项非常具有挑战性的任务，任何破坏性测量方法都会干扰失效模式，从而使其进一步复杂化。 进行准确、非破坏性的故障分析是每个锂离子电池制造商、OEM、经销商和最终客户的愿望。破坏性的测量方法，最终使电池无法工作，目前采用的手段，以确定故障的根本原因。非破坏性测试方法，如负载分析，目前对锂离子电池为什么或如何失败的了解很少。所提出的技术为客户提供了一种可重复的、非破坏性的数字测量方法，能够以多级方式对材料损坏进行定性或量化。 拟议的创新是一种电池故障测试系统，用于评估潜在的故障模式，并确定锂离子电池中的根本原因。该系统由软件和硬件组成。该软件包括一系列基于独特算法和将材料损伤机理应用于计算机模拟的概念的计算机模拟程序。硬件由一系列夹具、工作平台、仪器和计算机组成。 本项目中提出的数字测量技术是一种新颖的方法，具有以下独特功能：（1）以多级方式量化材料损伤，（2）考虑表面粗糙度的材料缺陷的有效重建，（3）用于高精度计量的精确去噪，（4）基于数字测量数据的多尺度/多物理场仿真的多级有限元网格划分。

The failure causes and mechanisms of lithium-ion (Li-ion) batteries are crucial in improving the reliability of batteries used in hybrid vehicles, military and aerospace applications. Failure analysis of Li-ion battery cells is a very challenging task that can be further complicated by the disturbance of failure modes by any destructive measurement methods. Conducting an accurate, non-destructive failure analysis is the desire of every Li-ion battery manufacturer, OEM, dealer, and end-customer. Destructive measurement methods, which ultimately render the battery inoperable, are currently employed as a means to determine root cause of failure. Non-destructive test methods, such as load analysis, currently provide little insight as to why or how a Li-ion battery is failing. The proposed technology offers the customer a repeatable, non-destructive methodology of digital measurement that is capable of qualifying or quantifying material damage at a multilevel fashion. The proposed innovation is a battery failure testing system for evaluating potential failure modes and identifying root causes of concern within Li-Ion batteries. This system consists of software and hardware. The software includes a series of computer simulation programs based on unique algorithms and the concept of applying material damage mechanism into computer simulation. The hardware is composed of a series of fixtures, working platforms, instruments, and computers. The digital measurement technology proposed in this project is a novel methodology with the following unique features: (1) quantification of material damage in a multilevel way, (2) effective reconstruction of material defects with consideration of surface roughness, (3) accurate de-noising for high precision metrology, and (4) multilevel finite element meshing for supporting multi-scale/multi-physics simulation based on digital measurement data.