Influence of Lithium Plating on the Mechanical Properties of Automotive High-Energy Pouch Batteries

Lithium plating (LP), as a specific degradation mechanism in lithium-ion batteries (LIBs), has been thoroughly investigated regarding formation conditions and potential safety hazards, but it is yet unknown how this effect influences the mechanical properties of batteries in the case of mechanical deformation. To address this issue, pouch cells used in EVs were artificially aged (AA) to a state of health of 80–82% in conditions that predominantly cause the formation of LP. These cells were subjected to a mechanical abuse load, and safety-relevant parameters, such as tolerated deformation level, failure force, and the process of thermal runaway (TR), were analyzed and compared with respective fresh (F) and aged cells of the same type. Complementary microscopy analyses were carried out to compare the found changed mechanical response with the different layer morphology caused by LP. The tests did exhibit a significantly different mechanical response of cells in the three states but also clearly altered short-circuiting behavior. The tolerated peak force at discharge state dropped by −28% and at charge state by −37% compared to fresh cells, while the deformation at failure slightly increased by +6% for the AA cells. A clear reduction in stiffness (−16%) of the LP cells was attributed to the formed layer, identified as mossy LP. The significantly stronger voltage drop at failure, seen for the LP cells, was associated with severe exothermal reactions of LP in contact with air and moisture during TR. This study revealed the strong influence of LP on the mechanical properties of LIBs. However, the transferability of the findings to other cell chemistries or formats is unclear, emphasizing the need for further investigations in this research field.