Lithium Battery Testing

The electric vehicle market is currently experiencing exponential growth in much of the world. With the share of global vehicle sales more than tripling in recent years, from 4% in 2020 to 14% in 2022¹, the demand for lithium-ion batteries is at an all-time high. Along with this demand, several new regulations for lithium-ion battery testing have been developed, leading to a demand for high throughput instrumentation and methodology for lithium-ion battery testing.

Some of the most widely used lithium battery testing standards or certifications include:

• UN/DOT 38.3 - aims to ensure the safety of lithium-ion batteries in shipping or transport and includes various tests including shock, vibration, impact, altitude, thermal testing, external short circuit, overcharge, and forced discharge.²
• IEC 62133 - establishes safety requirements for rechargeable lithium-ion cells for use in portable applications which includes testing guidelines related to charging, intended use, and reasonably foreseeable misuse.³
• CE Marking - required for lithium batteries sold in the EU, CE markings signify compliance with safety, health, and environmental protection requirements.⁴
• UL 1642 and UL 2054 - cover lithium-ion batteries and battery packs respectively and are recognized by the FDA’s Center for Devices and Radiological Health (CDRH) for use in medical devices.^5,6

While Li-ion batteries are commonly the focus of many laboratories and manufacturers thanks to their widespread use in consumer electronics and electric vehicles, other types of batteries are also tested for their safety and performance, including:

• Nickel Cadmium batteries (Ni-Cd)
• Sealed lead-acid batteries (Pb)
• Nickel metal hydride batteries (Ni-MH)

Why is Lithium Battery Testing Important?

With the global shift towards electric vehicles, the production of lithium-ion batteries is at an all-time high. A single lithium-ion battery pack can contain hundreds of individual cells and a flaw in any of these cells can have drastic impacts on the performance or safety of the battery. Risk mitigation measures including stringent quality control (QC) testing during manufacturing are of the utmost importance to maintain Li-ion battery performance and safety.

Li-ion battery analysis is also important to mitigate risks to both consumers and first responders when used for electrical vehicles. In the event of a crash, lithium batteries pose unique risks to these groups and their thorough research and testing are essential to mitigating these risks. Common risks of lithium-ion battery failure in electric vehicles include electric shock, thermal runaway, and stranded energy.⁷

What Instruments are Used for Lithium Battery Testing?

With the wide variety of tests required for battery testing, numerous types of instruments are required to meet regulatory compliance. Ranging from materials analysis equipment to mass spectrometers, a suite of analytical instruments is required by any laboratory or manufacturer when testing batteries. Instruments currently used for lithium battery testing can include:

• NMR spectrometers
• Raman spectrometers
• Analytical balances
• Moisture analysis equipment
• Microcalorimetry instruments
• Mass spectrometers
• Focused ion beam scanning electron microscopy

What are Key Considerations when Purchasing Battery Testing Instruments?

The type or scope of testing to be conducted will be the largest deciding factor when purchasing instruments for lithium battery testing. For raw materials analysis, ICP-MS and ICP-OES instruments are used to test lithium feedstocks and lithium brine solutions respectively. Another important aspect of battery testing is the analysis performed on the assembled battery. Mechanical testing instruments such as thermal analyzers, rheometers, and microcalorimetry instrumentation, play a critical role in ensuring lithium-ion battery stability and other mechanical properties. Lastly, optical assessment of lithium battery construction is commonly conducted to ensure proper construction and connection of the cells and other components. Specialized imaging instruments such as Short Wavelength InfraRed (SWIR) imaging systems and X-ray imaging systems are used throughout the manufacturing process to aid in this analysis.