Modeling and Characterization of Li-Ion 18650 Nickel–Cobalt–Alumina Battery Jellyroll Subjected to Static and Dynamic Compression Loading

This study presents a comprehensive experimental investigation of the mechanical response of the jellyroll and complete Li-ion 18650 Nickel–Cobalt–Alumina (NCA) battery under axial compression, highlighting the effects of strain rate and state-of-charge (SOC). The jellyroll was subjected to both static (1 mm/min) and dynamic (10–30 m/s) axial compression using a Split-Hopkinson Pressure Bar (SHPB). A key innovation of this work is the investigation of the role of electrolytes under both static and dynamic conditions, revealing their significant impact on stress and strain behavior due to hydrostatic pressure. Additionally, the complete NCA battery was tested under various SOC levels (0–75%) using flat plate compression. The results demonstrate the jellyroll’s sensitivity to strain rate, with increased stress responses at higher loading speeds. Furthermore, the inclusion of electrolytes markedly amplified the stress and strain response. The Fu-Chang model was successfully employed to numerically replicate the observed static and dynamic behaviors. Critically, the full battery tests revealed a negative correlation between voltage cutoff and SOC, with the risk of fire and explosion increasing at higher SOC levels. This research provides novel insights into the safety and mechanical resilience of Li-ion batteries under compression.