The popularity of electric vehicles (EVs) in the cold regions is seriously hindered by the degradation of lithium-ion batteries (LIBs) at low temperatures. To settle such issue, it is necessary to preheat the LIBs to moderate temperature for normal operation. As one of attractive internal preheating methods, pulse self-heating possesses high heating rate and efficiency. However, the application of pulse self-heating still faces the challenges of the pulse current power source unavailable in EVs. Herein we proposed a novel battery self-heating method which reuses the powertrain system of EVs to generate pulse excitation onboard, eliminating additional hardware. Moreover, the decoupled control of battery self-heating and motor torque was further developed to achieve the full-scene application, including charging, parking and driving. When applied in EVs, the proposed self-heating method could realize fast temperature rising of battery pack, shortening 30.7 % charging time at −20 °C compared with the conventional heat pump method. It also achieves rapid startup of EVs even at low temperature of −38 °C with high heating rate (0.73 °C min−1) and low energy consumption (4.2 % SOC), as well as maintains the dynamic performance during driving at −30 °C. The proposed method provides a promising solution to preheat the battery pack for EVs application at extremely low temperatures.
{"title":"Full-scene battery self-heating method based on powertrain system for electric vehicles at extremely low temperatures","authors":"Heping Ling, Lei Yan, Hua Pan, Siliang Chen, Fang Li, Shiyun Zhang","doi":"10.1016/j.etran.2025.100465","DOIUrl":"10.1016/j.etran.2025.100465","url":null,"abstract":"<div><div>The popularity of electric vehicles (EVs) in the cold regions is seriously hindered by the degradation of lithium-ion batteries (LIBs) at low temperatures. To settle such issue, it is necessary to preheat the LIBs to moderate temperature for normal operation. As one of attractive internal preheating methods, pulse self-heating possesses high heating rate and efficiency. However, the application of pulse self-heating still faces the challenges of the pulse current power source unavailable in EVs. Herein we proposed a novel battery self-heating method which reuses the powertrain system of EVs to generate pulse excitation onboard, eliminating additional hardware. Moreover, the decoupled control of battery self-heating and motor torque was further developed to achieve the full-scene application, including charging, parking and driving. When applied in EVs, the proposed self-heating method could realize fast temperature rising of battery pack, shortening 30.7 % charging time at −20 °C compared with the conventional heat pump method. It also achieves rapid startup of EVs even at low temperature of −38 °C with high heating rate (0.73 °C min<sup>−1</sup>) and low energy consumption (4.2 % SOC), as well as maintains the dynamic performance during driving at −30 °C. The proposed method provides a promising solution to preheat the battery pack for EVs application at extremely low temperatures.</div></div>","PeriodicalId":36355,"journal":{"name":"Etransportation","volume":"26 ","pages":"Article 100465"},"PeriodicalIF":17.0,"publicationDate":"2025-12-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145096466","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2025-12-01Epub Date: 2025-09-11DOI: 10.1016/j.etran.2025.100466
Yizhao Gao, Simona Onori
Accurate state-of-charge (SOC) estimation for lithium iron phosphate () batteries remains challenging due to their inherently flat open-circuit voltage (OCV)–SOC characteristics, which impair observability for conventional voltage-based and equivalent circuit model (ECM) methods. To address this limitation, we propose a DQV-based SOC estimation framework that uses short-duration current pulses to extract informative voltage features. Complete DQV–SOC reference curves are constructed offline across multiple C-rates ( 1/30C, 0.2C, 0.5C, 1C, and 2C). During operation, voltage responses from brief current pulses are processed via exponential fitting to generate smooth, noise-resilient DQV segments. These segments are fused with the reference data within an Unscented Kalman Filter (UKF), enabling closed-loop SOC estimation with low computational overhead. Experimental results highlight the significant influence of C-rates on the DQV-based SOC estimator. We observe that pulse currents significantly enhance SOC estimation convergence across the full SOC range [0, 1]. However, employing a single C-rate pulse may not ensure robustness across diverse SOC ranges, emphasizing the importance of carefully selecting C-rates to achieve SOC estimation convergence throughout the entire SOC range of [0, 1]. This research contributes to advancing reliable management practices for batteries in electric vehicles.
{"title":"Advancing SOC estimation in LiFePO4 batteries: Enhanced dQ/dV curve and short-pulse methods","authors":"Yizhao Gao, Simona Onori","doi":"10.1016/j.etran.2025.100466","DOIUrl":"10.1016/j.etran.2025.100466","url":null,"abstract":"<div><div>Accurate state-of-charge (SOC) estimation for lithium iron phosphate (<span><math><msub><mrow><mi>LiFePO</mi></mrow><mrow><mn>4</mn></mrow></msub></math></span>) batteries remains challenging due to their inherently flat open-circuit voltage (OCV)–SOC characteristics, which impair observability for conventional voltage-based and equivalent circuit model (ECM) methods. To address this limitation, we propose a DQV-based SOC estimation framework that uses short-duration current pulses to extract informative voltage features. Complete DQV–SOC reference curves are constructed offline across multiple C-rates (<span><math><mo>±</mo></math></span> 1/30C, <span><math><mo>±</mo></math></span> 0.2C, <span><math><mo>±</mo></math></span> 0.5C, <span><math><mo>±</mo></math></span> 1C, and <span><math><mo>±</mo></math></span> 2C). During operation, voltage responses from brief current pulses are processed via exponential fitting to generate smooth, noise-resilient DQV segments. These segments are fused with the reference data within an Unscented Kalman Filter (UKF), enabling closed-loop SOC estimation with low computational overhead. Experimental results highlight the significant influence of C-rates on the DQV-based SOC estimator. We observe that pulse currents significantly enhance SOC estimation convergence across the full SOC range [0, 1]. However, employing a single C-rate pulse may not ensure robustness across diverse SOC ranges, emphasizing the importance of carefully selecting C-rates to achieve SOC estimation convergence throughout the entire SOC range of [0, 1]. This research contributes to advancing reliable management practices for <span><math><msub><mrow><mi>LiFePO</mi></mrow><mrow><mn>4</mn></mrow></msub></math></span> batteries in electric vehicles.</div></div>","PeriodicalId":36355,"journal":{"name":"Etransportation","volume":"26 ","pages":"Article 100466"},"PeriodicalIF":17.0,"publicationDate":"2025-12-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145096464","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2025-12-01Epub Date: 2025-09-12DOI: 10.1016/j.etran.2025.100479
Yiheng Pang , Rui Gao , Yujiang Song , Hui Xu , Yun Wang
High catalyst cost impedes PEM fuel cell (PEMFC) commercialization, making the development of high-performance non-platinum(Pt) group metal (PGM) cathode catalyst layers (CLs) critical for advancing fuel cell technology. CLs contribute to a major portion of PEMFCs cost due to the use of PGM catalysts. To reduce the cost, non-PGM catalysts offer a viable alternative to low-Pt loading. In this study, we develop a three-dimensional (3-D) model to investigate the reaction rate, oxygen, and liquid water distributions in PEMFCs with a focus on the non-PGM cathode catalyst layer, which provides unique insights into electrochemically coupled transport processes that cannot be resolved by reduced-dimension or experimental approaches. Experiments were conducted using two types of non-PGM catalysts, including Fe-N-C and Mn-N-C based materials, to validate the 3-D model predictions. It is shown that CL properties such as catalyst materials, porosity, and ionomer content can play important roles in PEMFCs voltage gain, highlighting the performance impact of non-PGM catalysts. Large variations in the liquid water and oxygen contents occur in the gas diffusion layer from the land to channel under 1 A/cm2. The through-plane distributions under the channel show large spatial variations across the non-PGM CLs in oxygen and the electrolyte phase potential. Liquid water shows little change across the catalyst layer based on the 3-D model prediction. These findings advance PEMFC development by informing the design of durable, high-performance non-PGM CLs to reduce fuel cell cost for transportation applications.
{"title":"Three-dimensional modeling with experimental validation of non-PGM polymer electrolyte membrane fuel cells","authors":"Yiheng Pang , Rui Gao , Yujiang Song , Hui Xu , Yun Wang","doi":"10.1016/j.etran.2025.100479","DOIUrl":"10.1016/j.etran.2025.100479","url":null,"abstract":"<div><div>High catalyst cost impedes PEM fuel cell (PEMFC) commercialization, making the development of high-performance non-platinum(Pt) group metal (PGM) cathode catalyst layers (CLs) critical for advancing fuel cell technology. CLs contribute to a major portion of PEMFCs cost due to the use of PGM catalysts. To reduce the cost, non-PGM catalysts offer a viable alternative to low-Pt loading. In this study, we develop a three-dimensional (3-D) model to investigate the reaction rate, oxygen, and liquid water distributions in PEMFCs with a focus on the non-PGM cathode catalyst layer, which provides unique insights into electrochemically coupled transport processes that cannot be resolved by reduced-dimension or experimental approaches. Experiments were conducted using two types of non-PGM catalysts, including Fe-N-C and Mn-N-C based materials, to validate the 3-D model predictions. It is shown that CL properties such as catalyst materials, porosity, and ionomer content can play important roles in PEMFCs voltage gain, highlighting the performance impact of non-PGM catalysts. Large variations in the liquid water and oxygen contents occur in the gas diffusion layer from the land to channel under 1 A/cm<sup>2</sup>. The through-plane distributions under the channel show large spatial variations across the non-PGM CLs in oxygen and the electrolyte phase potential. Liquid water shows little change across the catalyst layer based on the 3-D model prediction. These findings advance PEMFC development by informing the design of durable, high-performance non-PGM CLs to reduce fuel cell cost for transportation applications.</div></div>","PeriodicalId":36355,"journal":{"name":"Etransportation","volume":"26 ","pages":"Article 100479"},"PeriodicalIF":17.0,"publicationDate":"2025-12-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145096463","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2025-12-01Epub Date: 2025-09-19DOI: 10.1016/j.etran.2025.100472
Dongmin Kim, Kitae Jang
In battery electric vehicles (BEV), energy originates in the battery and is transmitted to the wheels through a series of energy conversion processes involving the inverter and motor. Therefore, understanding the energy conversion mechanisms in both the inverter and motor is essential for accurately modeling energy consumption. However, in previous studies, real-world driving data are often limited, making it challenging to fully analyze the complex and nonlinear relationships within each conversion component. In this study, we collected input–output data from the inverters and motors of fifty-four BEVs, measured repeatedly over time. The data revealed a piecewise nonlinear relationship between input and output, prompting us to partition the models by different phases: propulsion, regeneration, and battery status. For each phase, we applied linear mixed-effects models to account for the hierarchical structure of the data, estimating coefficients separately for the inverter and motor using a randomly selected 75% of the dataset. Through this component-level modeling approach, the models not only capture component-level random-effect parameters but also effectively model the nonlinear energy conversion characteristics at the component level. The two models were then integrated to estimate the total driving energy consumption of the BEVs, and the results were validated against actual observations using the total driving energy from the remaining 25% of the dataset. Model performance was evaluated using the Total Consumption Estimation Rate (TCER) and Mean Absolute Percentage Error (MAPE). The proposed model achieved at least 95.27% in TCER and 86.34% in MAPE, outperforming existing approaches with a 20% higher TCER and an MAPE approximately ten times lower on average. The comparison demonstrated that our model accurately estimates driving energy consumption, as it effectively captured the heterogeneous and nonlinear relationships between input and output energy for each component.
{"title":"Component-level analysis for developing an energy consumption model for battery electric vehicles (BEVs) in operation","authors":"Dongmin Kim, Kitae Jang","doi":"10.1016/j.etran.2025.100472","DOIUrl":"10.1016/j.etran.2025.100472","url":null,"abstract":"<div><div>In battery electric vehicles (BEV), energy originates in the battery and is transmitted to the wheels through a series of energy conversion processes involving the inverter and motor. Therefore, understanding the energy conversion mechanisms in both the inverter and motor is essential for accurately modeling energy consumption. However, in previous studies, real-world driving data are often limited, making it challenging to fully analyze the complex and nonlinear relationships within each conversion component. In this study, we collected input–output data from the inverters and motors of fifty-four BEVs, measured repeatedly over time. The data revealed a piecewise nonlinear relationship between input and output, prompting us to partition the models by different phases: propulsion, regeneration, and battery status. For each phase, we applied linear mixed-effects models to account for the hierarchical structure of the data, estimating coefficients separately for the inverter and motor using a randomly selected 75% of the dataset. Through this component-level modeling approach, the models not only capture component-level random-effect parameters but also effectively model the nonlinear energy conversion characteristics at the component level. The two models were then integrated to estimate the total driving energy consumption of the BEVs, and the results were validated against actual observations using the total driving energy from the remaining 25% of the dataset. Model performance was evaluated using the Total Consumption Estimation Rate (TCER) and Mean Absolute Percentage Error (MAPE). The proposed model achieved at least 95.27% in TCER and 86.34% in MAPE, outperforming existing approaches with a 20% higher TCER and an MAPE approximately ten times lower on average. The comparison demonstrated that our model accurately estimates driving energy consumption, as it effectively captured the heterogeneous and nonlinear relationships between input and output energy for each component.</div></div>","PeriodicalId":36355,"journal":{"name":"Etransportation","volume":"26 ","pages":"Article 100472"},"PeriodicalIF":17.0,"publicationDate":"2025-12-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145158651","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2025-12-01Epub Date: 2025-09-17DOI: 10.1016/j.etran.2025.100477
Baoji Wang , Teng Xu , Bailin Zheng , Yue Kai , Kai Zhang
With the rapid development of intelligent technologies in aviation, electric vertical take-off and landing (eVTOL) aircraft have emerged as key players in the low-altitude economy, their battery performance directly impacts safety and cost, making accurate prediction essential. This paper presents a comprehensive review of the literature on battery degradation prediction methods for eVTOL aircraft, providing a brief overview on early modeling approaches and placing primary emphasis on recent advances in their applicability and limitations under unique operational scenarios of eVTOL, such as frequent takeoffs and landings, high power loads, and complex environmental conditions. Current prediction efforts primarily target key indicators including battery lifespan, health status, and capacity retention, employing a range of technical approaches such as electrochemical modeling, equivalent circuit modeling, data-driven algorithms like machine learning and deep learning, and hybrid physics-informed models that integrate domain knowledge with data analysis. The review systematically summarizes the main prediction methods and their evolution in different phases of the development of eVTOL technology. On this basis, we highlight existing technical bottlenecks and unresolved challenges, including the high demand for data and computational resources limiting real-time performance, poor accuracy of traditional models under high discharge rates and extreme conditions, challenges in accurately modeling complex multi-physics interactions and achieving a stable balance among prediction accuracy, interpretability, and real-time computational efficiency, as well as the scarcity of historical flight data affecting model reliability and generalization. This review also proposes future research directions to enhance the reliability and accuracy of battery degradation forecasting for eVTOL applications.
{"title":"Predicting battery degradation for electric vertical take-off and landing (eVTOL) aircraft: A comprehensive review of methods, challenges, and future trends","authors":"Baoji Wang , Teng Xu , Bailin Zheng , Yue Kai , Kai Zhang","doi":"10.1016/j.etran.2025.100477","DOIUrl":"10.1016/j.etran.2025.100477","url":null,"abstract":"<div><div>With the rapid development of intelligent technologies in aviation, electric vertical take-off and landing (eVTOL) aircraft have emerged as key players in the low-altitude economy, their battery performance directly impacts safety and cost, making accurate prediction essential. This paper presents a comprehensive review of the literature on battery degradation prediction methods for eVTOL aircraft, providing a brief overview on early modeling approaches and placing primary emphasis on recent advances in their applicability and limitations under unique operational scenarios of eVTOL, such as frequent takeoffs and landings, high power loads, and complex environmental conditions. Current prediction efforts primarily target key indicators including battery lifespan, health status, and capacity retention, employing a range of technical approaches such as electrochemical modeling, equivalent circuit modeling, data-driven algorithms like machine learning and deep learning, and hybrid physics-informed models that integrate domain knowledge with data analysis. The review systematically summarizes the main prediction methods and their evolution in different phases of the development of eVTOL technology. On this basis, we highlight existing technical bottlenecks and unresolved challenges, including the high demand for data and computational resources limiting real-time performance, poor accuracy of traditional models under high discharge rates and extreme conditions, challenges in accurately modeling complex multi-physics interactions and achieving a stable balance among prediction accuracy, interpretability, and real-time computational efficiency, as well as the scarcity of historical flight data affecting model reliability and generalization. This review also proposes future research directions to enhance the reliability and accuracy of battery degradation forecasting for eVTOL applications.</div></div>","PeriodicalId":36355,"journal":{"name":"Etransportation","volume":"26 ","pages":"Article 100477"},"PeriodicalIF":17.0,"publicationDate":"2025-12-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145158654","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2025-12-01Epub Date: 2025-09-27DOI: 10.1016/j.etran.2025.100490
Mingzhe Zhou , Jinyu Yan , Qingfei Ren , Yongrou Zhang , Lingling Hu
The structural integrity of lithium-ion batteries (LIBs) under dynamic loading is critical to their safe deployment in electric transportation systems. While dry-state testing of battery components is common, the influence of liquid electrolyte on battery failure under dynamic loading remains largely unexplored. This study investigates the out-of-plane compressive behavior of lithium iron phosphate (LFP) pouch cells in both dry and electrolyte-saturated states across a wide range of strain rates (0.005/s to 2000/s), using quasi-static and Split Hopkinson Pressure Bar (SHPB) tests. High-speed imaging and transparent cell designs enabled real-time visualization of electrolyte migration and structural deformation. The results show that, although electrolyte presence has little effect under quasi-static loading, it significantly lowers peak stress, strain, and stiffness at elevated strain rates. Microscopy reveals that confined electrolyte flow induces internal pore pressure, accelerates microcrack initiation in separators and electrode coatings. A mechanistic framework is proposed to explain how fluid–solid interactions degrade structural integrity at high rates. The findings demonstrate that dry-state testing overestimates battery resilience under impact and highlight the need to account for electrolyte effects in crash safety assessments. This work provides new insights into battery failure mechanisms relevant to electric mobility and supports the development of impact-tolerant energy storage systems and more comprehensive testing protocols for crashworthiness analysis.
{"title":"Strain-rate-dependent failure behavior of lithium-ion batteries: Role of liquid electrolyte in impact safety","authors":"Mingzhe Zhou , Jinyu Yan , Qingfei Ren , Yongrou Zhang , Lingling Hu","doi":"10.1016/j.etran.2025.100490","DOIUrl":"10.1016/j.etran.2025.100490","url":null,"abstract":"<div><div>The structural integrity of lithium-ion batteries (LIBs) under dynamic loading is critical to their safe deployment in electric transportation systems. While dry-state testing of battery components is common, the influence of liquid electrolyte on battery failure under dynamic loading remains largely unexplored. This study investigates the out-of-plane compressive behavior of lithium iron phosphate (LFP) pouch cells in both dry and electrolyte-saturated states across a wide range of strain rates (0.005/s to 2000/s), using quasi-static and Split Hopkinson Pressure Bar (SHPB) tests. High-speed imaging and transparent cell designs enabled real-time visualization of electrolyte migration and structural deformation. The results show that, although electrolyte presence has little effect under quasi-static loading, it significantly lowers peak stress, strain, and stiffness at elevated strain rates. Microscopy reveals that confined electrolyte flow induces internal pore pressure, accelerates microcrack initiation in separators and electrode coatings. A mechanistic framework is proposed to explain how fluid–solid interactions degrade structural integrity at high rates. The findings demonstrate that dry-state testing overestimates battery resilience under impact and highlight the need to account for electrolyte effects in crash safety assessments. This work provides new insights into battery failure mechanisms relevant to electric mobility and supports the development of impact-tolerant energy storage systems and more comprehensive testing protocols for crashworthiness analysis.</div></div>","PeriodicalId":36355,"journal":{"name":"Etransportation","volume":"26 ","pages":"Article 100490"},"PeriodicalIF":17.0,"publicationDate":"2025-12-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145219601","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2025-12-01Epub Date: 2025-10-17DOI: 10.1016/j.etran.2025.100504
Jing Hu , Caiping Zhang , Haoteng Guo , Jing Xu , Linjing Zhang , Tao Zhu , Yanru Zhang
Electrolyte leakage poses serious safety risks by shortening service life and elevating the risk of thermal runaway. A comprehensive understanding of the failure mechanisms is essential for effective safety management. However, such studies are hindered by the lack of reliable fault imitation methods, poor reproducibility of experimental data, and the complexity of side reactions. To address these challenges, this paper proposes a systematic, analytical framework that integrates reproducible fault imitation, cell regeneration, and systematic in-situ and ex-situ analyses to investigate external behaviors and reveal the failure mechanisms. Failure scenarios are imitated by drilling holes into the annular indentation of the aluminum safety valve. In-situ analyses reveal nonlinear degradation behavior and severe kinetic deterioration, primarily attributed to the degradation of the solid electrolyte interphase (SEI). Ex-situ techniques, including cell regeneration and comprehensive material characterization, are employed to distinguish between the impacts of electrolyte depletion and electrode damage. Electrolyte depletion is identified as the primary failure mechanism, which drives severe kinetic degradation and ultimately causing battery performance deterioration or even failure. In contrast, the electrode structure remains largely intact. Moreover, regeneration experiments have confirmed that partial performance recovery can be achieved through electrolyte replenishment. These methods and findings are expected to offer valuable insights for battery fault detection and recycling strategies.
{"title":"Insights into the failure mechanisms of leaky lithium-ion batteries for electric vehicles by a systematic multiscale analytical framework","authors":"Jing Hu , Caiping Zhang , Haoteng Guo , Jing Xu , Linjing Zhang , Tao Zhu , Yanru Zhang","doi":"10.1016/j.etran.2025.100504","DOIUrl":"10.1016/j.etran.2025.100504","url":null,"abstract":"<div><div>Electrolyte leakage poses serious safety risks by shortening service life and elevating the risk of thermal runaway. A comprehensive understanding of the failure mechanisms is essential for effective safety management. However, such studies are hindered by the lack of reliable fault imitation methods, poor reproducibility of experimental data, and the complexity of side reactions. To address these challenges, this paper proposes a systematic, analytical framework that integrates reproducible fault imitation, cell regeneration, and systematic in-situ and ex-situ analyses to investigate external behaviors and reveal the failure mechanisms. Failure scenarios are imitated by drilling holes into the annular indentation of the aluminum safety valve. In-situ analyses reveal nonlinear degradation behavior and severe kinetic deterioration, primarily attributed to the degradation of the solid electrolyte interphase (SEI). Ex-situ techniques, including cell regeneration and comprehensive material characterization, are employed to distinguish between the impacts of electrolyte depletion and electrode damage. Electrolyte depletion is identified as the primary failure mechanism, which drives severe kinetic degradation and ultimately causing battery performance deterioration or even failure. In contrast, the electrode structure remains largely intact. Moreover, regeneration experiments have confirmed that partial performance recovery can be achieved through electrolyte replenishment. These methods and findings are expected to offer valuable insights for battery fault detection and recycling strategies.</div></div>","PeriodicalId":36355,"journal":{"name":"Etransportation","volume":"26 ","pages":"Article 100504"},"PeriodicalIF":17.0,"publicationDate":"2025-12-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145362273","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2025-12-01Epub Date: 2025-10-10DOI: 10.1016/j.etran.2025.100495
Zhen Liu , Mingjie Zhang , Kai Yang , Yuhong Jin , Hao Wang , Bin Wei , Jingbing Liu
Sodium-ion batteries (SIBs) have emerged as a promising complementary technology to lithium-ion batteries (LIBs), primarily due to their potential for cost-effectiveness and resource sustainability. However, the thermal safety of SIBs still needs to be evaluated, as it is crucial for their potential application in electric vehicles and energy storage fields. In this study, we systematically examine and compare the thermal runaway (TR) and gas venting behaviors of 185 Ah Cu-Fe-Mn-based sodium-ion (CFM) and 314 Ah LiFePO4 (LFP) batteries under overcharging and overheating conditions-factors. Experimental results indicate that the TR process in CFM batteries exhibits distinct characteristics when compared to LFP batteries. Under overcharging conditions, CFM batteries experience more severe temperature fluctuations than those observed during overheating-maximum TR temperatures reach 620.9 °C and 587.3 °C, respectively-significantly higher than those recorded in LFP batteries. The activation time of the safety valve is similar to the onset of TR in both scenarios. Gas analysis reveals that the primary gaseous compositions generated during TR in CFM batteries are comparable to those produced by LFP batteries, with total gas volumes measuring 397.6 L during overheating and 699.3 L during overcharging. Although CFM batteries demonstrate superior resistance to overcharging relative to LFP counterparts, their elevated TR temperatures coupled with substantial emissions of combustible gases-including hydrogen, carbon monoxide, and methane considerably heighten combustion and explosion risks. These results may contribute to safer integration of CFM batteries in future applications, such as in electric vehicles, charging station and energy storage systems.
钠离子电池(sib)已经成为锂离子电池(lib)的一种有前途的补充技术,主要是因为它们具有成本效益和资源可持续性的潜力。然而,sib的热安全性仍然需要评估,因为它对于其在电动汽车和储能领域的潜在应用至关重要。在这项研究中,我们系统地研究和比较了185 Ah cu - fe - mn基钠离子(CFM)和314 Ah LiFePO4 (LFP)电池在过充和过热条件下的热失控(TR)和排气行为。实验结果表明,与LFP电池相比,CFM电池的TR过程具有明显的特点。在过充条件下,CFM电池的温度波动比过热时更严重,最高TR温度分别达到620.9°C和587.3°C,显著高于LFP电池。在两种情况下,安全阀的激活时间与TR的开始时间相似。气体分析表明,CFM电池在TR过程中产生的主要气体成分与LFP电池相当,过热时的总气体体积为397.6 L,过充时的总气体体积为699.3 L。尽管CFM电池相对于LFP电池具有更强的抗过充能力,但其较高的TR温度加上大量可燃气体(包括氢气、一氧化碳和甲烷)的排放大大增加了燃烧和爆炸的风险。这些结果可能有助于CFM电池在未来的应用中更安全的集成,例如电动汽车、充电站和储能系统。
{"title":"Thermal runaway behavior of large-format sodium-ion and lithium-iron phosphate batteries under different trigger sources: A comparative study","authors":"Zhen Liu , Mingjie Zhang , Kai Yang , Yuhong Jin , Hao Wang , Bin Wei , Jingbing Liu","doi":"10.1016/j.etran.2025.100495","DOIUrl":"10.1016/j.etran.2025.100495","url":null,"abstract":"<div><div>Sodium-ion batteries (SIBs) have emerged as a promising complementary technology to lithium-ion batteries (LIBs), primarily due to their potential for cost-effectiveness and resource sustainability. However, the thermal safety of SIBs still needs to be evaluated, as it is crucial for their potential application in electric vehicles and energy storage fields. In this study, we systematically examine and compare the thermal runaway (TR) and gas venting behaviors of 185 Ah Cu-Fe-Mn-based sodium-ion (CFM) and 314 Ah LiFePO<sub>4</sub> (LFP) batteries under overcharging and overheating conditions-factors. Experimental results indicate that the TR process in CFM batteries exhibits distinct characteristics when compared to LFP batteries. Under overcharging conditions, CFM batteries experience more severe temperature fluctuations than those observed during overheating-maximum TR temperatures reach 620.9 °C and 587.3 °C, respectively-significantly higher than those recorded in LFP batteries. The activation time of the safety valve is similar to the onset of TR in both scenarios. Gas analysis reveals that the primary gaseous compositions generated during TR in CFM batteries are comparable to those produced by LFP batteries, with total gas volumes measuring 397.6 L during overheating and 699.3 L during overcharging. Although CFM batteries demonstrate superior resistance to overcharging relative to LFP counterparts, their elevated TR temperatures coupled with substantial emissions of combustible gases-including hydrogen, carbon monoxide, and methane considerably heighten combustion and explosion risks. These results may contribute to safer integration of CFM batteries in future applications, such as in electric vehicles, charging station and energy storage systems.</div></div>","PeriodicalId":36355,"journal":{"name":"Etransportation","volume":"26 ","pages":"Article 100495"},"PeriodicalIF":17.0,"publicationDate":"2025-12-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145266438","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2025-12-01Epub Date: 2025-10-13DOI: 10.1016/j.etran.2025.100494
Kyunghyun Kim , Kyeongeun Cho , Kwangho Lee , Junyoung Yoon , Jung-Il Choi
The traditional paradigm of battery research, primarily rooted in controlled laboratory experiments, is being fundamentally reshaped by the influx of real-world field data. Although laboratory tests remain indispensable for isolating specific electrochemical mechanisms, they fall short of capturing the complex phenomena that arise under practical operating conditions. Field data offers essential insights into this complexity by revealing the intricate interplay among dynamic loads, thermal transients, and path-dependent degradation—interactions often obscured in simplified test protocols. This discrepancy underscores a significant gap in understanding, highlighting that field data is not merely a validation tool, but a vital source for uncovering new physics governing battery performance and aging in realistic environments. Harnessing this potential requires addressing critical challenges—from data quality and privacy to the integration of emerging methodologies in feature engineering, fleet analytics, and physics-informed machine learning. This review surveys large-scale fleet datasets alongside high-resolution vehicle- and cell-level measurements, and examines methodologies spanning state estimation, fault detection, and energy optimization. These developments collectively point to a paradigm shift in battery research—from passive diagnostics toward proactive lifecycle management. Ultimately, this trajectory leads to generalized battery foundation models: continuously evolving digital twins that actively shape, rather than merely predict, a battery’s entire lifecycle.
{"title":"Battery field data and why it matters: Foundations for real-world electric vehicles","authors":"Kyunghyun Kim , Kyeongeun Cho , Kwangho Lee , Junyoung Yoon , Jung-Il Choi","doi":"10.1016/j.etran.2025.100494","DOIUrl":"10.1016/j.etran.2025.100494","url":null,"abstract":"<div><div>The traditional paradigm of battery research, primarily rooted in controlled laboratory experiments, is being fundamentally reshaped by the influx of real-world field data. Although laboratory tests remain indispensable for isolating specific electrochemical mechanisms, they fall short of capturing the complex phenomena that arise under practical operating conditions. Field data offers essential insights into this complexity by revealing the intricate interplay among dynamic loads, thermal transients, and path-dependent degradation—interactions often obscured in simplified test protocols. This discrepancy underscores a significant gap in understanding, highlighting that field data is not merely a validation tool, but a vital source for uncovering new physics governing battery performance and aging in realistic environments. Harnessing this potential requires addressing critical challenges—from data quality and privacy to the integration of emerging methodologies in feature engineering, fleet analytics, and physics-informed machine learning. This review surveys large-scale fleet datasets alongside high-resolution vehicle- and cell-level measurements, and examines methodologies spanning state estimation, fault detection, and energy optimization. These developments collectively point to a paradigm shift in battery research—from passive diagnostics toward proactive lifecycle management. Ultimately, this trajectory leads to generalized battery foundation models: continuously evolving digital twins that actively shape, rather than merely predict, a battery’s entire lifecycle.</div></div>","PeriodicalId":36355,"journal":{"name":"Etransportation","volume":"26 ","pages":"Article 100494"},"PeriodicalIF":17.0,"publicationDate":"2025-12-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145320598","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2025-12-01Epub Date: 2025-08-26DOI: 10.1016/j.etran.2025.100457
Kareem Abo Gamra, Igor Zlatković, Maximilian Zähringer, Christian Allgäuer, Markus Lienkamp
The growing need to decarbonize the transport sector can be addressed through wide-scale electrification, which is currently hampered by concerns regarding range anxiety and insufficient charging speeds. Therefore, it is critical to provide methodologies that ensure fast-charging capability regardless of route or ambient conditions. Model-based fast-charging and preconditioning strategies have been shown to offer a robust approach to achieve short charging times without endangering battery safety or longevity. However, they must be scaled to the vehicle application while considering factors such as route infrastructure and energy constraints. In this study, we utilize a dynamic programming approach to optimize a charge stop and preconditioning strategy for long-distance journeys. The methodology is validated by performing long-distance travel experiments on a route of 850 km using a Tesla Model 3 Standard Range, revealing that charging time can be reduced by 24 min while simultaneously consuming less thermal management energy compared to the onboard route planning algorithm. A simulation study with a hypothetical high-power cell using an anode potential control charging protocol to prevent lithium plating shows that the inherent self-heating behavior could be leveraged to achieve a charge time reduction of 50 min compared to the reference, while requiring almost no active preconditioning. Optimizing the vehicle speed between charging stations additionally allows total travel duration and energy consumption to be adjusted based on charging constraints and individual preferences regarding the value of time and energy costs.
{"title":"Holistic thermal management and charge stop optimization using model-based fast-charging strategies","authors":"Kareem Abo Gamra, Igor Zlatković, Maximilian Zähringer, Christian Allgäuer, Markus Lienkamp","doi":"10.1016/j.etran.2025.100457","DOIUrl":"10.1016/j.etran.2025.100457","url":null,"abstract":"<div><div>The growing need to decarbonize the transport sector can be addressed through wide-scale electrification, which is currently hampered by concerns regarding range anxiety and insufficient charging speeds. Therefore, it is critical to provide methodologies that ensure fast-charging capability regardless of route or ambient conditions. Model-based fast-charging and preconditioning strategies have been shown to offer a robust approach to achieve short charging times without endangering battery safety or longevity. However, they must be scaled to the vehicle application while considering factors such as route infrastructure and energy constraints. In this study, we utilize a dynamic programming approach to optimize a charge stop and preconditioning strategy for long-distance journeys. The methodology is validated by performing long-distance travel experiments on a route of 850<!--> <!-->km using a Tesla Model 3 Standard Range, revealing that charging time can be reduced by 24<!--> <!-->min while simultaneously consuming less thermal management energy compared to the onboard route planning algorithm. A simulation study with a hypothetical high-power cell using an anode potential control charging protocol to prevent lithium plating shows that the inherent self-heating behavior could be leveraged to achieve a charge time reduction of 50<!--> <!-->min compared to the reference, while requiring almost no active preconditioning. Optimizing the vehicle speed between charging stations additionally allows total travel duration and energy consumption to be adjusted based on charging constraints and individual preferences regarding the value of time and energy costs.</div></div>","PeriodicalId":36355,"journal":{"name":"Etransportation","volume":"26 ","pages":"Article 100457"},"PeriodicalIF":17.0,"publicationDate":"2025-12-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145118546","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}