Thermal runaway (TR) and its propagation (TRP) pose critical risks in the application of large-format lithium-ion batteries in heavy-duty electric vehicles. In this work, we apply a computational approach using a lumped heat release model. This model is calibrated with experimental data from accelerating rate calorimetry (ARC) and TRP tests to investigate battery aging effects on TR and TRP. It is seen that the simulations can effectively reproduce key experimental observations, such as TR onset temperature, maximum temperature, and TRP time. Furthermore, the influence of battery aging on TR behavior is investigated, specifically solid–electrolyte interphase (SEI) growth and electrolyte degradation. The findings reveal that aging significantly accelerates TR onset while lowering the heat release of batteries. The interplay between accelerated SEI layer growth and electrolyte degradation significantly influences TRP dynamics. Compared to new batteries, the total TRP time initially decreases during early aging, reaching 78% of the original TRP time at around 80% state of health (SOH). During late aging, TRP time slightly increases to 85% of the original time at 50% SOH. This computational approach provides crucial insights into the dynamic safety of aged batteries with regard to different combinations of electrolyte degradation and SEI thickness growth rate.
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