Influence of Aging on Thermal Runaway Behavior of Lithium-Ion Batteries: Experiments and Simulations for Engineering Education

This study investigates the impact of aging on the thermal runaway behavior of lithium-ion batteries. By combining external heating tests, cone calorimetry experiments, and numerical simulations, the thermal runaway characteristics of LFP and NMC batteries at different SOH levels (100%, 90%, 80%) were systematically evaluated. Experimental results show a non-monotonic effect of aging on thermal runaway: mildly aged batteries (90% SOH) exhibited the earliest TR trigger and highest risk due to unstable SEI film growth, while new batteries (100% SOH) released the most energy. Significant differences were observed between battery chemistries: LFP batteries displayed fluctuating temperature curves indicating a staged buffering mechanism, whereas NMC batteries had smooth heating but abrupt energy release. Cone calorimeter tests revealed that aged LFP batteries had multi-stage HRR curves, while NMC batteries showed consistent HRR profiles; mass loss data confirmed reduced active material consumption with aging. Numerical simulations integrating SEI decomposition and other reactions validated the impact of aging on internal processes. The study recommends prioritizing monitoring of moderately aged batteries, optimizing early-warning systems for NMC batteries, and preventing secondary explosions, providing support for safety assessments of aged batteries.