The Fraunhofer Institute for High-Speed Dynamics, Ernst-Mach-Institut, describes its innovative X-ray technology as a ‘globally unique high-speed X-ray system’. According to scientists at the institute, it reveals what happens inside large-format battery cells in fractions of a second under stress – and could help accelerate the development of safer cell generations for the European automotive industry.
The approach aims to answer what occurs inside a battery cell when it fails. Until now, cell manufacturers and vehicle integrators have relied on simulations, destructive testing methods, or indirect measurements. However, the method developed by Fraunhofer EMI now enables a direct view into the operating cell. According to the team, the system combines high-performance X-ray technology with a specially developed battery test chamber and comprehensive sensor technology for the simultaneous recording of temperature, pressure, voltage, and gas flow: “Recording up to 1,000 images per second, it reveals processes such as gas formation, material displacement, and crack propagation inside the cell at extremely high resolution—events that until now have remained hidden from view.”
Dr Sebastian Schopferer, Head of Battery Safety at Fraunhofer EMI, emphasises: “Our in-situ method allows us to see what happens inside a cell in fractions of a second—in real time and at the highest resolution. This fundamentally changes how we understand battery design and safety.” A key engineering achievement was the development of a protective chamber that reliably shields sensitive X-ray components from the extreme conditions during the thermal runaway of lithium-ion cells.
