Search NASA⌕ Search

SEARCH · Search NASA

Results for “runaway”

Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

Quote a phrase for an exact phrase match. Source license links do not imply unrestricted reuse.

At least 55 records · Page 3
All sourcesNASA NTRSDOE OSTI
DOE OSTI2021

Unlocking the self-supported thermal runaway of high-energy lithium-ion batteries

Layered Ni-rich LiNi x Mn y Co 1-x-y O 2 (NMC) materials are the most promising cathode materials for Li-ion batteries due to their favorable energy densities. However, the low thermal stability typically caused by detrimental oxygen release leads to significant safety concerns. Determining the pathways of oxygen evolution reaction is essential, as the ideal safety countermeasure is to break the reaction chain of thermal runaway. In this study, we demonstrate that two endogenous pathways of oxygen involved in strong exothermic reactions lead the NMC811|graphite pouch cell to an uncontrollable state, and we quantify the individual contribution of the pathways to thermal runaway. Approximately 41% of thermal-induced oxygen reacts aggressively with ethylene carbonate (EC) at the cathode/electrolyte interface with 16% heat generation, accelerating the self-heating rate and thereby further triggering thermal runaway. The residual oxygen that survives the reaction with carbonate spreads to the lithiated anode with major heat generation (65%), bringing the battery to the maximum destructive temperature during thermal runaway. By confirming the significant roles of EC and anode, a deeper understanding on battery fire was achieved. Finally, the revealed mechanism can help guide studies on stopping the two reaction pathways, allowing for the safer use of high-energy lithium-ion batteries in the future.

25 ENERGY STORAGE↗
DOE OSTI2021

Thermal runaway mechanism of lithium-ion battery with LiNi 0.8 Mn 0.1 Co 0.1 O 2 cathode materials

Battery safety is critical to the application of lithium-ion batteries, especially for high energy density battery applied in electric vehicles. In this paper, the thermal runaway mechanism of LiNi 0.8 Co 0.1 Mn 0.1 O 2 based lithium-ion battery is illustrated. And the reaction between cathode and flammable electrolyte is proved as the trigger of the thermal runaway accident. In detail, with differential scanning calorimeter tests for battery components, the material combination contributing to thermal runaway was decoupled. Characterization with synchrotron X-ray diffraction and transmission electron microscopy with in-situ heating proved that the vigorous exothermic reaction is initiated by the liberated oxygen species. The pulse of highly active oxygen species reacted quickly with the electrolyte, accompanied with tremendous heat release, which accelerated the phase transformation of charged cathode. Also, the mechanism is verified by a confirmatory experiment when the highly active oxygen species were trapped by anion receptor, the phase transformation of the charged cathode was inhibited. Clarifying the thermal runaway mechanism of LiNi 0.8 Co 0.1 Mn 0.1 based lithium-ion battery may light the way to battery chemistries of both high energy density and high safety.

25 ENERGY STORAGE↗
DOE OSTI2026

Quantitative Analysis and Prediction of Thermal Runaway Metrics of High-Nickel Oxide Cathodes by Machine Learning Models

The pursuit of higher energy density in lithium-ion batteries has made high-nickel (Ni) layered oxides leading cathode candidates for next-generation electric vehicles. However, their poor thermal stability, particularly at Ni contents ≥ 90%, increases the risk of cathode-initiated thermal runaway. Furthermore, we present a data-driven framework combining linear and nonlinear machine learning models to predict key thermal runaway descriptors from a high-throughput differential scanning calorimetry database. With cathode composition and state of charge (SOC) as input features, the ensemble model accurately predicts peak temperature, heat release, and peak heat flow. SHAP analysis identifies Ni content and SOC as the dominant factors controlling thermal runaway temperature, while SOC primarily governs heat release and peak heat flow. Al, Mg, and Mn improve thermal stability by strengthening metal–oxygen bonding and delaying structural transformation, whereas B mainly reduces heat release through surface passivation. Validation with a new cathode composition confirms accurate prediction of SOC-dependent thermal runaway behavior and critical SOC.

25 ENERGY STORAGE↗
DOE OSTI2021

Compressional Alfvén eigenmodes excited by runaway electrons

Compressional Alfvén eigenmodes (CAEs) driven by energetic ions have been observed in magnetic fusion experiments. In this paper, we show that the modes can also be driven by runaway electrons formed in post-disruption plasma, which may explain kinetic instabilities observed in DIII-D disruption experiments with massive gas injection. The spatial structure is calculated, as are the frequencies which are in agreement with experimental observations. Using a runaway electron distribution function obtained from a kinetic simulation, the mode growth rates are calculated and found to exceed the collisional damping rate when the runaway electron density exceeds a threshold value. The excitation of CAEs poses a new possible approach to mitigate seed runaway electrons during the current quench and surpassing the avalanche.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2020

Understanding Li-Ion Cell Internal Short Circuit and Thermal Runaway through Small, Slow and In Situ Sensing Nail Penetration

Here we report a small, slow and in situ sensing (3S) nail penetration test method to understand Li-ion cell internal short circuit (ISC) and thermal runaway. The method not only keeps conventional nail penetration's advantage of simple implementation, but also enhances its relevance to field failures and enables detailed in situ diagnosis. It was applied to 3-Ah pouch cells and revealed insights that could not be captured by conventional methods. Most interestingly, multiple in situ temperature peaks were observed during a period of over 100 s before thermal runaway. These initial peaks exceeded safety limit but the temperature rapidly decreased after each peak instead of causing immediate thermal runaway. Further investigation suggested that the initial temperature peaks occurred when nail tip reached aluminum foil current collector to form a low resistance ISC between anode and aluminum foil. The rapid temperature decrease after each peak can be attributed to sudden drop of ISC current, which can be further attributed to rupture of aluminum foil and increase of contact resistance. The findings show that 3S nail penetration test can separate processes of ISC from thermal runaway and provide details of ISC at the level of individual electrode and current collector.

25 ENERGY STORAGE↗
DOE OSTI2024

Simulation of DIII-D disruption with argon pellet injection and runaway electron beam

Abstract The next generation of large tokamaks, including ITER, will be equipped with a disruption mitigation system (DMS) that can be activated if a disruption is deemed to be imminent. Introducing impurities by pellet (large or shattered) or massive gas injection has been shown to be an effective mitigation mechanism on many tokamaks. The goal of the mitigation is to lessen the thermal and electromagnetic loads from the disruption without generating enough high-energy (runaway) electrons to damage the device. Variations of this mitigation process with impurity injection are presently being tested on many experiments. We have modeled one such impurity injection experiment on DIII-D using the M3D-C1 nonlinear 3D extended MHD code (Jardin et al 2012 Comput. Sci. Discovery 6 014002), The model includes an argon large pellet injection and ablation model, impurity ionization, recombination, and radiation, and runaway electron formation and subsequent evolution, including both Dreicer and avalanche sources. We obtain reasonable agreement with the experimental results for the timescale of the thermal and current quench and for the magnitude of the runaway electron plateau formed during the mitigation. This is the first 3D full MHD simulation with pellets and REs to simulate the disruption process and it also provides a partial validation of the M3D-C1 DMS model.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2024

Effects of Trigger Method on Fire Propagation during the Thermal Runaway Process in Li-ion Batteries

Lithium-ion batteries are prone to fire hazards due to the possibility of thermal runaway propagation. During battery product development and subsequent safety tests for design validation and safety certification, the thermal runaway onset is triggered by various test methods such as nail penetration, thermal ramp, or external short circuit. This failure initiation method affects the amount of heat contributions and the composition of gas generations. This study compares two such trigger methods, external heating and using a thermally-activated internal short circuit device (ISCD). The effects of the trigger method on total heat generation are experimentally investigated within 18650 cylindrical cells at single cell level as well as at multiple cell configuration level. The severity of failure was observed to be worse for cells with ISCDs at single cell level, whereas quite the opposite results were observed at multiple cell configuration level. A preliminary numerical analysis was performed to better understand the battery safety performance with respect to thermal runaway trigger methods and heat transfer conditions.

25 ENERGY STORAGE↗
DOE OSTI2021

Modeling cell venting and gas-phase reactions in 18650 lithium ion batteries during thermal runaway

A numerical model is developed to study cell venting, internal pressure, and gas-phase dynamics behavior of 18650 Li-ion cells undergoing thermal runaway. A k-e Reynolds-Averaged Navier-Stokes (RANS) model is adopted to describe the turbulent flow out of the cells, while the fluid dynamics inside the cells is described by Darcy-Forchheimer's equation. Thermal abuse reactions and gas generation kinetics are described by a single-step lumped reaction model. Then, a series of computational fluid dynamics (CFD) simulations are conducted on a single 18650 cell at various states-of-charge (100%, 50%, 25%) to study detailed flow and thermal behavior as a function of quantity of gas generated during cell venting. Venting events are categorized into two stages: i) breaching of the cell container and ii) thermal runaway reactions. It is found that the cell response is dominated by the second stage since most of the gases are generated during thermal runaway. Also, the propensity for propagation is highly affected by state-of-charge (SOC). Cells at higher SOCs produce more heat and gas during the venting event, owing to higher mass and concentrations of reacting gases, and consequently reach higher internal cell pressures which increase the risk of side-wall breaching.

25 ENERGY STORAGE↗
DOE OSTI2022

Avoiding thermal runaway in lithium-ion batteries using ultrasound detection of early failure mechanisms

Thermal runaway leading to catastrophic failure has slowed the adoption of lithium-ion batteries, highlighting the need for early warning systems. In this work, ultrasound is used to detect physical changes in 0.950 Ah Li-ion battery cells by inducing conditions associated with thermal runaway. Ultrasound signal features are extracted as the batteries are cycled under baseline conditions and subsequently subjected to constant current and voltage overcharges. Two conditions identifying failure are defined: a warning to detect the start of overcharge and an emergency stop (E-stop), to immediately take the battery out of service. Using changes in ultrasound signal features, consistent warning and stopping classifications are applied to all failure experiments. On average, a warning notification was issued after 15% of the overcharge time and an E-stop was triggered after 35% of total overcharge duration before failure. Further testing suggests that it is possible to avoid thermal runaway by reacting to intermediate, warning notifications prior to an immediate E-stop. In other words, not only can detection derived by ultrasound identify battery failure before a catastrophic event, but can also provide early, actionable warnings so that overcharges can be detected and corrected quickly enough so the battery does not need to be decommissioned.

25 ENERGY STORAGE↗
DOE OSTI2022

Compressible battery foams to prevent cascading thermal runaway in Li-ion pouch batteries

Lithium-ion battery packs require thermal management to achieve optimum life and safety. This is becoming crucial for battery packs composed of high-energy-density cells. Pouch cells themselves achieve highest packaging efficiency but require additional structural support and thermal management when grouped into modules, especially under abusive conditions such as thermal runaway. Novel foam battery pads have demonstrated to cushion volume changes of pouch cells and are reengineered in this study to mitigate cell-to-cell thermal runaway propagation. The compressible pads are made of polyurethane foams incorporating flame-retardant additives or coatings, including intumescent and fire wall materials. Here their performances were evaluated by conducting nail penetration tests on modules composed of pouch cells at 100% state of charge (SOC), with the foams placed in between the cells. Experimental results show cascading thermal runaway was considerably delayed by polyurethane foams incorporating flame-retardant additives or coatings. Complete prevention of cascading failure was achieved with dense polyurethane foams with multilayered coatings of both fire wall and intumescent materials.

25 ENERGY STORAGE↗
DOE OSTI2024

Exploring thermal runaway propagation in Li-ion batteries through high-speed X-ray imaging and thermal analysis: Impact of cell chemistry and electrical connections

Battery safety design is important to consider from the individual Li-ion cell to the level of the macro-system. On the macro-level, failure in one single cell can lead to propagation of the thermal runaway and rapidly set a whole battery pack on fire. Factors that can impact the propagation outcome, such as cell model/chemistry and electrical connection are here investigated using a combination of measurements. Several abusive tests were conducted, combining two different cell models (Molicel P42A and LG M50, both 21700s) in series and parallel connections (16 tests per configuration). Overall, a propagation outcome of 56% was measured from the 32 conducted tests, a minimum temperature of 150 °C was required to initiate propagation, and the fastest propagation occurred in 123 s. Temperature measurements were higher in series connected cells, initiating the discussion of cell chemistry and internal resistance on this effect. The difference in current-flow during thermal runaway in series and parallel connections, and how this can affect the temperature evolution is further discussed. Spatio-temporal mapping of X-ray radiography allowed us to derive the speed of thermal runaway evolution inside the battery and has shown that series connected cells, in particular P42A, occur faster. It was further observed that deviant sidewall behaviors such as temperature-induced breaches and pressure-induced ruptures occurred in P42As only respective nail-penetrated cells only.

25 ENERGY STORAGE↗
DOE OSTI2026

Gas-driven short disconnection mitigates thermal runaway in Li-ion batteries under mechanical abuse

Mechanical abuse poses a critical safety risk to Li-ion batteries by inducing internal short circuits that initiate thermal runaway. Remarkably, voltage recovery frequently emerges during thermal runaway initiation, a phenomenon that conventional theories fail to explain. Here, our study develops a new multiphysics mechanism to explain voltage recovery, termed gas-driven short disconnection, whereby internal gas pressure mechanically disengages short-circuit contacts and causes the cell voltage to rebound. This mechanism incorporates gas generation and its structural impact on the short circuit. Real-time optical and thermal imaging and X-ray computed tomography reveal fluid-structure interaction between internal gas flow and adjacent shorting contacts. We establish a mechanistic framework linking gas-driven short disconnection to cell-level voltage and temperature responses, elucidating the extension–truncation pattern of voltage recovery. Furthermore, thermal regime maps show that a voltage recovery duration exceeding 5 s correlates with limited temperature rise below 150 °C, indicating that sustained short-circuit disconnection suppresses Joule heating. Additionally, a dimensionless criterion is deduced from scaling analysis for physical plausibility of gas-driven short disconnection in mechanically abused cells. This finding inspires smart venting control, which regulates gas release to maintain the internal pressure while dissipating gas enthalpy, thereby providing a device-level strategy for thermal runaway mitigation.

Gas-driven short disconnection↗
DOE OSTI2022

Lagrangian particle simulation of hydrogen pellets and SPI into runaway electron beam in ITER

Numerical studies of the ablation of pellets and shattered pellet injection (SPI) fragments into a runaway electron beam in ITER have been performed using a time-dependent pellet ablation code [Samulyak et al., Nucl. Fusion, 61(4), 046007 (2021)]. The code resolves detailed ablation physics near pellet fragments and large-scale expansion of ablated clouds. The study of a single-fragment ablation quantifies the influence of various factors, in particular, the impact ionization by runaway electrons and cross-field transport models, on the dynamics of ablated plasma and its penetration into the runaway beam. Simulations of SPI performed using different numbers of pellet fragments study the formation and evolution of the ablation clouds and their large-scale dynamics in ITER. In conclusion, the penetration depth of the ablation clouds is found to be of the order of 50 cm.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2023

Nonlinear saturation of whistler modes driven by runaway electrons

Runaway electrons exhibit kinetic instabilities with potentially beneficial consequences. The anomalous Doppler resonance between the electrons and whistler modes is a primary underlying mechanism. These instabilities require a first-principle nonlinear theoretical analysis, which would ultimately enable assessment of their impact on disruption mitigation and diagnostics, especially in ITER-relevant conditions. This paper presents recent progress in developing the required theoretical framework for isolated nonlinear resonances. By employing the generic bump-on-tail model, we predict the wave saturation levels in both near-threshold and strongly driven regimes. Remarkably, for the waves of interest, the parallel component of the wave vector dictates the parallel momentum of the resonant particles. This feature, together with the expected wave saturation level, provides a complete description of the resonance impact on the runaway electron distribution function. We show that the parametric dependence of the nonlinearly saturated mode provides a way to recover certain features of the runaway momentum distribution function.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2024

The battery failure databank: Insights from an open-access database of thermal runaway behaviors of Li-ion cells and a resource for benchmarking risks

The thermal response of Li-ion cells can greatly vary for identical cell designs tested under identical conditions, the distribution of which is costly to fully characterize experimentally. The open-source Battery Failure Databank presented here contains robust, high-quality data from hundreds of abuse tests spanning numerous commercial cell designs and testing conditions. Data was gathered using a fractional thermal runaway calorimeter and contains the fractional breakdown of heat and mass that was ejected, as well as high-speed synchrotron radiography of the internal dynamic response of cells during thermal runaway. The distribution of thermal output, mass ejection, and internal response of commercial cells are compared for different abuse-test conditions, which when normalized on a per amp-hour basis show a strong positive correlation between heat output from cells, the fraction of mass ejected from the cells, their energy- and power-density. Ejected mass was shown to contain 10x more heat per gram than non-ejected mass. The causes of 'outlier' thermal and ejection responses i.e., extreme cases, are elucidated by high-speed radiography which showed how occurrences such as vent clogging can create more hazardous conditions. High-speed radiography also demonstrated how the time-resolved interplay of thermal runaway propagation and mass ejection influences the total heat generated.

25 ENERGY STORAGE↗
DOE OSTI2020

Structure and overstability of resistive modes with runaway electrons

In this paper, we investigate the effects of runaway electron current on the dispersion relation of resistive magnetohydrodynamic modes in tokamaks. We present a new theoretical model to derive the dispersion relation, which is based on the asymptotic analysis of the resistive layer structure of the modes. It is found that in addition to the conventional resistive layer, a new runaway current layer can emerge whose properties depend on the ratio of the Alfvén velocity to the runaway electron convection speed. Due to the contribution from this layer, both the tearing mode and kink mode will have a real frequency in addition to a growth rate. The derived dispersion relation has been compared with numerical results using both a simplified eigenvalue calculation and a M3D-C 1 linear simulation, and good agreement is found in both cases.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2020

Pellet sublimation and expansion under runaway electron flux

This work provides a qualitative description of the pellet response to the ambient runaway electrons. For ITER-relevant parameters, our estimates suggest that the cryogenic pellets will be sublimated instantly at the edge of the runaway beam. The subsequent rapid expansion of the sublimated material spreads the impurities over the poloidal cross-section of a tokamak on a millisecond time scale prior to the complete ionization of the expanding cloud. Here, the injected solid pellet turns into a rapidly expanding gas cloud before it reaches the core of the runaway beam. As a result, the pellet acts similar to the massive gas injection.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2021

Toroidal modeling of runaway avalanche in DIII-D discharges

Abstract A toroidal modeling tool is developed to study the runaway electron (RE) avalanche production process in tokamak plasmas, by coupling the Rosenbluth–Putvinski avalanche model (Rosenbluth and Putvinski 1997 Nucl. Fusion 37 1355) with an n = 0 magneto-hydrodynamic (MHD) solver. Initial value numerical simulations are carried out for two DIII-D discharges with different plasma shapes (one near circular, and the other with high elongation). It is found that, assuming the same level of about 1% seed current level, the Rosenbluth–Putvinski model somewhat underestimates the RE plateau current for the circular-shaped plasma, as compared with that measured in DIII-D experiments. For an elongated, higher current plasma, simulations find strong runaway current avalanche production despite the lack of measured plateau RE current in experiments. A possible reason for this discrepancy is a lack of additional RE dissipation physics in the present two-dimensional model. Systematic scans of the plasma boundary shape, at fixed pre-disruption plasma current, find that the plasma elongation helps to reduce the RE avalanche production, confirming recent results obtained with an analytic model (Fülöp et al 2020 J. Plasma Phys. 86 474860101). The effect of the plasma triangularity (either positive or negative), on the other hand, has a minor effect. On the physics side, the avalanche process involves two competing mechanisms associated with the electric field. On the one hand, a stronger electric field produces a higher instantaneous avalanche growth rate. On the other hand, a fast growing RE current quickly reduces the fraction of the conduction current together with the electric field, and hence a faster dissipation of the poloidal flux. As a final result of these two dynamic processes, the runaway plateau current is not always the largest with the strongest initial electric field. These results lay the foundation for future self-consistent inclusion of the MHD dynamics and the RE amplification process.

Physics↗