Thermal runaway and other battery failures pose significant risks, though safeguards have made such events relatively rare. The National Laboratory of the Rockies (NLR), a U.S. Department of Energy facility, is conducting comprehensive research to prevent failures by examining batteries at every stage of their operational life.
NLR’s approach begins with characterizing the materials that comprise batteries, measuring microstructural, thermal, electrical, mechanical, and electrochemical properties. This work feeds into a new open-access Battery Safety Database developed in collaboration with the University of Texas at Austin and Exponent Inc., supported by the Advanced Research Project Agency-Energy (ARPA-E). Researchers deliberately stress-test batteries through nail penetration, thermal stress, and internal short circuits to understand failure mechanisms under controlled conditions.
The research employs multiscale analysis linking atomic-level defects to particle behavior and thermal management within cells. Advanced imaging techniques, including a nano-computed tomography scanner unique to NLR, allow real-time monitoring of battery function and failure. These capabilities are complemented by data analytics and artificial intelligence models that can predict behaviors such as thermal runaway. The objective assessments and publicly releasable data from nonproprietary projects help accelerate battery innovation across the industry.
As emerging battery chemistries promise higher energy density at lower material costs, NLR’s work has expanded under the ARPA-E JOULES program, recently expanded to JOULES-1K, to evaluate next-generation technologies including sodium, potassium-ion, and solid-state lithium metal batteries. Beyond laboratory research, NLR is collaborating with the National Highway Traffic Safety Administration to support emergency responders handling electric vehicle incidents, particularly following events like the post-flood battery fires from Hurricane Ian in 2022. This includes evaluating diagnostic and discharge tools and developing improved guidance and resources for first responders.