Teardown
and FMEA
Battery Anatomy and Failure Analysis
CORE OFFERINGS
Physical Teardowns
Our expert technicians perform meticulous disassembly of battery cells, modules, and packs in a controlled environment. This process involves the careful documentation of dimensions and assembly methods for each component, including component selection and architecture for electronic boards, as well as internal materials composition. We provide detailed photographic and microscopic documentation of the internal structure, identifying any visible defects, anomalies, or signs of degradation. This initial physical examination lays the groundwork for further analysis and the FMEA process.
Battery Cells Analysis
Following the cell teardown, individual cell components (electrodes, separator, electrolyte, current collectors, housing, etc.) are carefully examined. This may involve visual inspection under magnification, dimensional measurements, and material characterization techniques. The goal is to identify any manufacturing defects (e.g., tears, wrinkles, contamination), signs of premature degradation (e.g., corrosion, delamination), or inconsistencies in material quality that could contribute to potential failures.
Failure Mode and Effects Analysis (FMEA)
Our experienced team conducts a systematic FMEA, considering the design and construction of the battery as revealed during the teardown. This involves identifying potential failure modes for each component (e.g., separator rupture, electrode cracking, electrolyte leakage), analyzing their potential causes (e.g., mechanical stress, thermal abuse, manufacturing defects), and evaluating their effects on battery performance, safety, and reliability. We assess the severity, likelihood of occurrence, and detectability of each failure mode to prioritize potential risks and recommend mitigation strategies.
Cross-Sectional Analysis
To gain deeper insights into the internal structure and material interfaces, we prepare cross-sections of battery components. These samples are meticulously polished to reveal the layered structure and interfaces between different materials. Scanning Electron Microscopy examination, often coupled with Energy-Dispersive X-ray Spectroscopy (EDS), allows for the analysis of layer thickness, materials distribution, and the identification of any interfacial issues (e.g., poor adhesion, diffusion layers) that could contribute to failure.
Documentation and Reporting
We provide comprehensive reports that detail the entire teardown process, including photographic and microscopic documentation. The report includes a detailed analysis of the components, identified defects, and the findings of the FMEA, outlining potential failure modes, their causes, effects, and recommended actions. Our reports provide actionable insights to improve battery design, manufacturing processes, and overall safety and reliability.
OUR Teardown and FMEA
CAPABILITIES INCLUDE:
- Controlled environment for teardown procedures to prevent contamination.
- High-resolution photographic and microscopic documentation at each stage.
- Precise identification and cataloging of all battery components and materials.
- Expert-led FMEA sessions facilitated by experienced battery engineers.
- Thorough assessment of manufacturing quality and identification of potential defects.
- Identification of potential failure mechanisms based on physical evidence and FMEA.
- Comprehensive reporting with clear findings, risk assessments, and actionable insights.