Quality assurance in lithium-ion battery manufacturing using X-ray computed tomography


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Battery cell and module development for electric vehicle (EV) applications is experiencing exponential growth. Multiple varieties of battery cell sizes, architectures, and modules are developed, tested, produced, and are already in application within EV battery packs. Battery component manufacturers and cell and automotive OEMs need to ensure that all batteries brought into the market fulfill general quality and reliability requirements, are safe to use by consumers, and that failures are detected early before any danger arises for users.
X-ray based computed tomography (CT) is applied to test and inspect lithium-ion batteries (LIB) during R&D, production, and later in application. The technology offers unique capabilities to detect hidden failures and to improve the safety and visibility of potentially dangerous anomalies. Furthermore, advancements in state-of-the-art data analytics and process automation enable increased productivity while maintaining the desired quality.
This presentation will focus on the applications of industrial CT in the battery cell and module industry and provide insight, real images, and analytics of failures in battery cells and, if possible, modules. Failures such as voids in electrodes, foreign material, overhang, and welding issues are identified as well as methods of detecting these failures.
Furthermore, an outlook will be given on technologies that enable the scanning of complete EV battery packs without assembly as well as the advantages of CT for the EV battery second life market.

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