Overcharge-to-thermal-runaway behavior and safety assessment of commercial lithium-ion cells with different cathode materials: A comparison study

Abstract In this paper, overcharge behaviors and thermal runaway (TR) features of large format lithium-ion (Li-ion) cells with different cathode materials (LiFePO4 (LFP), Li[Ni1/3Co1/3Mn1/3]O2 (NCM111), Li[Ni0.6Co0.2Mn0.2]O2 (NCM622) and Li[Ni0.8Co0.1Mn0.1]O2 (NCM811)) were investigated. The results showed that, under the same overcharge condition, the TR of LFP Li-ion cell occurred earlier compared with the NCM Li-ion cells, indicating its poor overcharge tolerance and high TR risk. However, when TR occurred, LFP Li-ion cell exhibited lower maximum temperature and mild TR response. All NCM Li-ion cells caught fire or exploded during TR, while the LFP Li-ion cell only released a large amount of smoke without fire. According to the overcharge behaviors and TR features, a safety assessment score system was proposed to evaluate the safety of the cells. In short, NCM Li-ion cells have better performance in energy density and overcharge tolerance (or low TR risk), while LFP Li-ion cell showed less severe response to overcharging (or less TR hazards). For NCM Li-ion cells, as the ratio of nickel in cathode material increases, the thermal stability of the cathode materials becomes poorer, and the TR hazards increase. Such a comparison study on large format Li-ion cells with different cathode materials can provide deeper insights into the overcharge behaviors and TR features, and provide guidance for engineers to reasonably choose battery materials in automotive applications.