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CT Inspection of Battery Systems

Définition

non-destructive CT analysis of high-voltage batteries at cell, module and system level for electromobility

Synonymes:
Battery Inspection CTCell CTHV Battery TestingAccumulator CT

What is CT Inspection of Battery Systems?

CT inspection of battery systems covers the non-destructive three-dimensional analysis of lithium-ion accumulators at all levels: individual cell, module and battery pack. As a core component of electromobility, battery systems are subject to the highest safety and quality requirements. CT enables visualisation of internal structures that would only be accessible by destroying the specimen using conventional methods.

Scientific background

At cell level, electrode-separator composites are examined for delamination, dendrite formation and short-circuit risks. At module level, cell alignment, connection quality and contacting are in focus. For battery packs, CT provides information on housing integrity, cooling channel geometry and joining technology. The low contrast ratio between active material and separator requires special scan and reconstruction parameters.

Relevant key metrics

  • Voxel size: 1–10 µm for electrode/separator resolution; 50–200 µm for module level.
  • Critical defect types: dendrites detectable from ~10 µm (micro-CT), delamination from ~50 µm gap width.
  • Contrast limitation: lithium-rich materials absorb weakly; optimisation via scan energy and detector choice.

Standards and thresholds

  • Standards: IEC 62660 (secondary cells for electric vehicles), UN 38.3 (transport), ISO 12405-4 (performance tests for EV batteries), UL 2580 (batteries for electric vehicles).
  • Typical thresholds: Trapped foreign particles > 50 µm are considered critical; delamination > 5 % of electrode area is often a rejection criterion.
  • Validity: Safety-relevant assembly testing; inspection scope and acceptance criteria are defined per customer specification and application class.

Application in industrial practice

  • Production-accompanying incoming and outgoing inspection of cells and modules.
  • Failure analysis after thermal runaway without further safety risk.
  • Process qualification for new cell chemistries (solid-state, NMC, LFP).

Sources and reference date

  • IEC 62660-1:2018.
  • ISO 12405-4:2018.
  • UL 2580:2020.
  • UN 38.3 (Transport of dangerous goods).
  • Reference date: March 2026.

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