White Paper: Test & Measurement
Battery Failure Analysis: Identifying the Root Cause of Power System Failures
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This technical paper offers a comprehensive overview of battery failure analysis methods used to uncover the root cause of performance, safety, or leakage issues in battery-powered systems. Designed for engineers, technical leads, and product developers, the paper explains the full investigative process from initial situation appraisal through physical teardown, cell dissection, and chemical evaluation.
Intertek outlines the most commonly used techniques across seven diagnostic pillars, including non-destructive X-ray, electrical and impedance characterization, BMS review, autopsy under inert atmosphere, and analytical chemistry using FTIR, GC-MS, and SEM-EDS. The paper also discusses how to simulate suspected failure conditions through targeted abuse and aging tests, and emphasizes the importance of replicating failure mechanisms in the lab to confirm root cause.
A section on manufacturing audits highlights the value of digging deeper than standard checklist assessments, and using Socratic questioning to probe technical processes. This method often reveals overlooked design, material, or quality control flaws that contribute to product failures.
Whether you are investigating the root cause of a field failure or validating the reliability of a new design, this guide offers a proven roadmap for battery failure analysis across chemistries and applications.
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Overview
The Battery Failure Analysis white paper by Intertek outlines the systematic process of identifying the root causes of failures in battery-powered devices. It emphasizes the complexity of battery technology and the necessity for expert knowledge across various scientific and engineering disciplines to conduct effective failure analyses.
The document begins with an introduction to failure analysis, which involves collecting and analyzing data to determine the reasons behind a failure. This process is crucial for implementing corrective actions, improving future product designs, and addressing liability claims. The paper highlights that battery failures can stem from issues related to the battery or cell itself, the device's external components, or the battery management system (BMS).
Key elements of the failure analysis process include:
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Situation Appraisal: This initial step involves gathering detailed information about the failure, including its circumstances and background. Tools such as the "5 Whys" and Ishikawa Diagrams are employed to clarify facts and identify contributing factors.
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Examination of Batteries and Cells: This section covers various examination techniques, including physical inspections, electrical and performance characterizations, and chemical analyses. Non-destructive methods like X-ray imaging are also discussed.
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Simulation of Suspected Faults: Testing suspected faults and misuse scenarios helps in understanding potential failure modes.
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Manufacturing Audits: These audits assess the production processes to identify any quality control issues that may lead to failures.
The paper concludes by underscoring the importance of a tailored approach to failure analysis, as no single method applies universally across all battery types and failure modes. Intertek’s extensive experience in this field positions it as a leading provider of independent third-party assistance, ensuring that clients receive precise and actionable insights to enhance battery safety and performance.