Risk Assessment of Retired Lithium-Ion Battery Packs: FMEA and Pugh Matrix Integration

The widespread use of lithium-ion batteries across various applications, from automotive to heavy vehicles and energy storage systems, has made assessing the structural condition of these components a complex challenge. The harsh operating environments and diverse usage patterns during their first life turn these batteries into a "black box," making it difficult to evaluate their integrity and safety, especially when considering their potential for circularity. This paper seeks to identify potential failures in retired lithium-ion battery at different levels (i.e. pack, module and cell) and assessing their impact and severity. First, adaptive Failure Modes and Effects Analysis (FMEA) is applied to evaluate battery system failures. Furthermore, the Pugh Matrix is used to compare and select the appropriate non-destructive testing (NDT) methods, considering factors such as cost and time with the severity at different levels. The proposed approach is validated with the industrial partner and the results will contribute to the development of safety protocols, ensure efficient disassembly and support decisions related to battery circularity.