Analysis of failure behavior and safety performance on sodium-ion batteries under dynamic loads
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摘要: 钠离子电池因资源丰富和成本优势成为储能领域的重要发展方向，但其机械滥用下的安全性研究仍显不足。本研究以
18650 商用钠离子电池为对象，采用试验与模拟相结合的方法，系统研究了其在径向挤压下的失效机理。同时建立均质化有限元模型模拟其动态冲击（1~35 m/s）行为，并引入应力波理论分析其失效机理。结果表明，在准静态挤压下电池峰值载荷点与失效点高度吻合。挤压速度提升使峰值载荷增加，失效位移增大，但对0%荷电状态（state of charge, SOC）电池温升影响微弱。在动态冲击中，失效位移随冲击速度提高而减小，且在20 m/s后急剧下降；裂纹位置表现出明显的速度依赖性，从低速（<15 m/s）的中部，移至20 m/s的底部，并在30 m/s以上转移至冲击端，该行为主要由应力波的传播与反射叠加控制。可见，钠离子电池失效由结构失稳引发内短路导致，SOC主导低速挤压温升，而高速失效行为受应力波支配。所建模型可有效预测宏观力学响应，为电池安全设计提供重要依据。Abstract: Sodium-ion batteries (SIBs) have emerged as a promising candidate for energy storage applications owing to their material abundance and cost-effectiveness; however, safety issues under mechanical abuse conditions remain insufficiently understood. This study systematically investigates the failure mechanisms of commercial18650 sodium-ion batteries subjected to radial compression by integrating experimental and numerical approaches. Experiments were conducted using an electronic universal testing machine to characterize the mechanical–electrical–thermal responses at different compression speeds and states of charge (SOC), with synchronous measurements of load, voltage, and temperature. A homogenized finite element model was established to simulate the dynamic crushing behavior at impact velocities ranging from 1 to 35 m/s. The failure mechanisms were interpreted based on stress wave theory, and the failure criteria were calibrated using the experimental results. The results indicate that under quasi-static loading, the battery exhibits a four-stage deformation process, in which the peak load coincides with the onset of failure. With increasing compression velocity, both the peak load and the failure displacement increase, while the temperature rise of batteries at 0% SOC is only weakly affected. In contrast, higher SOC significantly intensifies the temperature rise and advances the occurrence of failure. Under dynamic impact conditions, the failure displacement decreases with increasing impact velocity and shows a pronounced reduction beyond 20 m/s, whereas the load–displacement curve exhibits a distinct plateau at high velocities. The crack initiation location displays a strong dependence on impact velocity: it originates in the central region at low velocities (<15 m/s), shifts to the bottom at approximately 20 m/s, and moves to the impact end when the velocity exceeds 30 m/s. This transition is mainly governed by the propagation, reflection, and superposition of stress waves. Overall, the results indicate that failure of sodium-ion batteries is triggered by structural instability leading to internal short circuits. The SOC primarily controls the thermal response under low-speed compression, whereas stress wave effects dominate the failure behavior at high impact velocities. The proposed model demonstrates good predictive capability for the macroscopic mechanical response and provides valuable insights for the safety design of sodium-ion batteries.-
Key words:
- sodium-ion battery /
- dynamic impact /
- failure behavior /
- finite element simulation
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图 2 不同挤压速度下电池的机械响应部分照片以及力、温度和电压变化曲线
Figure 2. Partial photos of mechanical responses and force-, temperature-, and voltage-displacement curves of batteries under different extrusion speeds
图 3 不同荷电状态下电池的力、电压和温度的变化曲线
Figure 3. Force, voltage and temperature curves at varying states of charge
图 5 模型构建及侧面网格示意图
Figure 5. Computational model setup and cross-sectional grid schematic
图 6 力-位移曲线及卷芯挤压对比
Figure 6. Force-displacement curves and comparative jelly-roll deformation
图 8 不同挤压速度下的力-位移曲线
Figure 8. Force-displacement curves of SIBs under different crush rates
表 1 模型材料参数
Table 1. Material model parameters
组件 材料类型 密度/(kg·m−3) 弹性模量/GPa 泊松比 外壳 Mat_24 7800 160 0.3 卷芯 Mat_63 1820 0.8 0.01 挤压板 Mat_20 7850 200 0.33 支撑板 Mat_20 7850 200 0.33 
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