The economic viability of lithium-ion batteries in portable and distributed power applications is increasingly constrained by premature degradation caused by irregular load profiles, mechanical vibration, and variable microclimatic exposure. These stressors elevate operational costs, shorten replacement cycles, and undermine return on investment across mobile energy systems. This study develops a multi-physics–driven degradation and economic assessment framework to quantify how coupled electrochemical, mechanical, and environmental effects translate into accelerated capacity loss and rising lifecycle costs in multi-cell battery modules. Moving beyond conventional thermal-centric analyses, the framework examines stress-induced solid electrolyte interphase (SEI) instability, lithium plating onset, and impedance growth under non-uniform operating conditions representative of hybrid and portable energy platforms. A dual-stage approach is employed: (i) electrochemical–mechanical coupling simulations using a pseudo-2D Newman model integrated with a stress–strain module in COMSOL to capture particle deformation, SEI cracking, and kinetic inefficiencies; and (ii) accelerated aging experiments combining vibration-assisted cycling, dynamic current ripple, and controlled humidity exposure on 18650-based modular packs. Results show that cyclic mechanical strain increases local overpotential by up to 18 %, accelerating lithium plating under low-state-of-charge, high-current regimes and reducing usable capacity retention, while high humidity conditions (>70 % RH) intensify electrolyte decomposition, increasing cell impedance by 22–34 % and raising energy losses per delivered kilowatt-hour. An economic degradation model coupled with a machine-learning prognostic algorithm predicts remaining useful life with an error below 6%, enabling optimization of operating envelopes to minimize replacement frequency and levelized battery cost. The findings demonstrate that mechanically induced electrochemical degradation constitutes a dominant driver of hidden economic loss, often exceeding thermal failure-related costs. The study concludes with economically oriented design and policy recommendations, including vibration-damping system architecture, humidity-adaptive battery management controls, and RUL-based operational limits, offering a scalable pathway to improve cost efficiency, asset longevity, and investment sustainability of lithium-ion battery systems.
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