Electric cycling is one of the major damage sources in lithium-ion batteries and extensive work has been produced to understand and to slow down this phenomenon. The damage is related to the insertion and extraction of lithium ions in the active material. These processes cause mechanical stresses which in turn generate crack propagation, material loss and pulverization of the active material. In this work, the principles of diffusion induced stress theory are applied to predict concentration and stress field in the active material particles. Coupled and uncoupled models are derived, depending on whether the effect of hydrostatic stress on concentration is considered or neglected. The analytical solution of the coupled model is proposed in this work, in addition to the analytical solution of the uncoupled model already described in the literature. The analytical solution is a faster and simpler way to deal with the problem which otherwise should be solved in a numerical way with finite difference method or a finite element model. The results of the coupled and uncoupled models for three different state of charge levels are compared assuming the physical parameters of anode and cathode active material. Finally, the effects of tensile and compressive stress are analysed.

The characterization of thickness change during operation of LFP/Graphite prismatic batteries is presented in this work. In this regard, current rate dependence, hysteresis behaviour between charge and discharge and correlation with phase changes are deepened. Experimental tests are carried out with a battery testing equipment correlated with optical laser sensors to evaluate swelling. Furthermore, thickness change is computed analytically with a mathematical model based on lattice parameters of the crystal structures of active materials. The results of the model are validated with experimental data. Thickness change is able to capture variations of the internal structure of the battery, referred to as phase change, characteristic of a certain state of charge. Furthermore, phase change shift is a characteristic of battery ageing. Being able to capture these properties with sensors mounted on the external surface the cell is a key feature for improving state of charge and state of health estimation in battery management system.

Nowadays, lithium-ion batteries are one of the most widespread energy storage systems, being extensively employed in a large variety of applications. A significant effort has been made to develop advanced materials and manufacturing processes with the aim of increasing batteries performance and preserving nominal properties with cycling. Nevertheless, mechanical degradation is still a significant damaging mechanism and the main cause of capacity fade and power loss. Lithium ions are inserted and extracted into the lattice structure of active materials during battery operation, causing the deformation of the crystalline lattice itself. Strain mismatches within the different areas of the active material caused by the inhomogeneous lithium-ions concentration induce mechanical stresses, leading ultimately to fracture, fatigue issues, and performance decay. Therefore, a deep understanding of the fracture mechanics in active materials is needed to meet the rapidly growing demand for next-generation batteries with long-term stability, high safety, excellent performance, and long life cycle. This review aims to analyze the fracture mechanics in the active material microstructure of electrodes due to battery operations from an experimental point of view. The main fracture mechanisms occurring in the common cathode and anode active materials are described, as well as the factors triggering and enhancing fracture. At first, the results obtained by performing microscopy and diffraction analysis in different materials are discussed to provides visual evidence of cracks and their relation with lattice structure. Then, fatigue phenomena due to crack growth as a function of the number of cycles are evaluated to assess the evolution of damage during the life cycle, and the effects of fracture on the battery performance are described. Finally, the literature gaps in the characterization of the fracture behavior of electrode active materials are highlighted to enhance the development of next-generation lithium-ion batteries.