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As battery-powered devices become increasingly common—from smartphones and laptops to electric vehicles and scooters—concerns over battery safety are mounting. A recent wave of high-profile battery fires has highlighted the need for better detection of hidden defects that could lead to dangerous malfunctions. Now, researchers at Drexel University are introducing a novel, cost-effective solution: using ultrasound to peer inside batteries without dismantling them.
Detailed in the journal Electrochimica Acta, the team’s method adapts ultrasound—a technique historically used in fields like medicine and geophysics—to examine the internal mechanical and chemical behavior of lithium-ion batteries. By sending low-energy sound waves through the battery structure, the technology detects subtle changes in wave speed and behavior, which can indicate flaws such as gas pockets, dry areas, material separation, or other internal defects, according to TechXplore.
Traditional battery inspection relies heavily on visual checks and select cell performance testing. While high-resolution X-ray imaging is also used, it’s often costly and time-intensive, limiting its use in large-scale production environments. The ultrasound method proposed here is not only faster and more economical, but it also provides real-time feedback and can be deployed during both manufacturing and R&D phases.
The Drexel team demonstrated the system using a benchtop ultrasonic tool, designed to be simple enough for integration into existing workflows—particularly for companies producing large volumes of battery cells, such as electric vehicle manufacturers. The method doesn’t interfere with battery operation, and the data can be captured continuously during battery use.
Crucially, the researchers developed accompanying open-source software that simplifies operation and provides automated analysis of the data. This lowers the technical barrier for engineers and allows for quicker diagnostics during battery development.
The team is already working on future enhancements, including three-dimensional imaging capabilities and scanning tools. With demand for lithium-ion cells growing rapidly, technologies like this could become key to improving both safety and performance—before dangerous defects make it into the hands of consumers.
