Study of the fire behavior of high-energy lithium-ion batteries with full-scale burning test

A full-scale burning test is conducted to evaluate the safety of large-size and high-energy 50 Ah lithium–iron phosphate/graphite battery pack, which is composed of five 10 Ah single cells. The complex fire hazards associated with the combustion process of the battery are presented. The battery combustion behavior can be summarized into the following stages: battery expansion, jet flame, stable combustion, a second cycle of a jet flame followed by stable combustion, a third cycle of a jet flame followed by stable combustion, abatement and extinguishment. The multiple jets of flame indicate serious consequences for the battery and pose a challenge for battery safety. The battery ignites when the battery temperature reaches approximately 175–180 °C. This critical temperature is related to an internal short circuit of the battery, which results from the melting of the separator. The maximum temperature of the flame can reach 1500 °C. The heat release rate (HRR) varies based on the oxygen generated by the battery and the Joule effect of the internal short circuit. The HRR and heat of combustion can reach 49.4 kW and 18,195.1 kJ, respectively. The state of charge of the battery has a significant effect on the maximum HRR, the overall heat generation and the mass loss of the battery.