Session: 09-16-03: Energy-Related Multidisciplinary III

Paper Number: 164098

Mechanical Abuse and Safety in Sodium-Ion Batteries 

Sodium-ion batteries (SIBs) are gaining significant attention as promising alternatives to lithium-ion batteries (LIBs) due to their low cost, abundant raw materials, and potential for large-scale energy storage applications. As the demand for sustainable energy solutions grows, SIBs present an attractive option for reducing reliance on lithium, which is expensive and geographically constrained. However, despite these advantages, the safety and reliability of SIBs under mechanical abusive loading remain largely unexplored. A comprehensive understanding of their failure mechanisms is essential to ensure their safe deployment in various applications. Unlike LIBs, which have been extensively studied for their mechanical, thermal, and electrochemical stability, SIBs require further investigation to determine how mechanical impacts influence their structural integrity, electrochemical performance, and thermal runaway risks. Addressing this knowledge gap is critical for advancing SIB technology and facilitating its commercialization.

In this study, we conduct a systematic experimental and computational investigation into the mechanical-electrochemical-thermal behavior of SIBs under mechanical abuse. Specifically, we employ ball indentation tests to examine the mechanical response of SIBs under different loading conditions. Furthermore, to gain deeper insights into the underlying mechanisms governing their failure, we develop a multiphysics coupling computational framework. This framework integrates a 3D mechanical model, a 3D thermal model, an electrochemical model, and an internal short circuit (ISC) model, enabling a comprehensive analysis of the complex interactions between mechanical deformation, heat generation, and electrochemical responses within the battery. Using this advanced computation approach, we systematically evaluate key factors that influence battery safety, including the effects of ball size, battery aspect ratio, and ball loading position. Additionally, we perform a comparative study of SIBs and LIBs to assess their relative safety and failure characteristics under mechanical abuse by the computational framework.

Our experimental results reveal that during ISC, the battery temperature increases gradually, reaching approximately 35 °C. This relatively low temperature rise is attributed to the rapid voltage drop and the inherently lower energy capacity of SIBs compared to LIBs, which results in reduced heat generation. Parametric studies demonstrate that increasing the steel ball size or decreasing the battery aspect ratio can significantly delay the ISC trigger and lower the peak ISC temperature, thereby improving battery safety. Moreover, computational results indicate that SIBs exhibit a slightly delayed ISC initiation and significantly lower ISC temperatures compared to LIBs, suggesting that SIBs possess an inherent safety advantage in scenarios involving mechanical impact. These findings underscore the importance of structural design and material selection in enhancing the mechanical resilience and thermal stability of SIBs.

Overall, this study provides a fundamental understanding of the mechanical abuse behavior of SIBs and offers a robust computational framework for evaluating their safety under various impact conditions. The insights gained from this research contribute to the development of safer, more reliable, and commercially viable sodium-ion battery technologies. By establishing guidelines for mitigating ISC risks and optimizing battery design, this study supports the advancement of next-generation sustainable energy storage solutions, paving the way for broader adoption of SIBs in commercial and industrial applications.

Presenting Author: Bo Rui University of Delaware

Presenting Author Biography: Mr. Bo Rui is a Ph.D student of Energy Mechanics and Sustainability Laboratory (EMSLab) & Department of Mechanical Engineering in University of Delaware. And Bo obtained his M.S. at Shanghai University (major in Solid Mechanics). His research interest is in multiphysics modeling of battery safety.

Authors:

Bo Rui University of Delaware
Shuguo Sun University of Delaware
Xijun Tan University of Delaware
Jun Xu University of Delaware