Ultrasound scanner detects fire-starting battery flaws in seconds

Researchers at Drexel University have developed a novel ultrasound-based diagnostic tool that rapidly detects internal defects in lithium-ion batteries, such as gas pockets, structural flaws, dry zones, and misaligned components. These defects can lead to battery failure, overheating, or thermal runaway, which are significant safety risks for devices ranging from smartphones to electric vehicles. Unlike traditional X-ray imaging, which is slow, costly, and limited in scope, this ultrasound technique uses scanning acoustic microscopy to send low-energy sound waves through battery cells, revealing internal mechanical and structural features without disrupting battery function. The new method addresses the limitations of current quality checks, which rely on visual inspections, sample testing, and X-rays, by providing a faster, lower-cost, and more sensitive alternative. Given the rapid growth in battery-powered devices and electric vehicles, the risk of defective cells entering the market has increased, making improved detection methods crucial. The Drexel team also created open-source software to control the ultrasound instrument and facilitate quick data analysis, aiming to