Multi‐Physics Hazard Modeling for Battery Safety: Flammability, Venting Gas Ignition, and Arcing

ABSTRACT Battery cell, module, and pack safety are critical for electric vehicles. In this study, thermal runaway and arcing are modeled by evaluating flammability, ignition, and breakdown voltage while incorporating multiple vent–gas species and ejected particles. A methodology is developed to assess flammability, breakdown voltage, and arc‐generation capability with and without particles, including particle‐based ignitability and particle‐ignited vent–gas combustion. Simulations on simple geometries and a full battery pack highlight system‐level hazards. The flammability region is about 70% larger using mixture‐based evaluation, whereas breakdown voltage is roughly 30% lower for vent–gas compositions and decreases further in particle‐laden conditions.