Battery research depends upon up-to-date information on the cell characteristics found in current electric vehicles, which is exacerbated by the deployment of novel formats and architectures. This necessitates open access to cell characterization data. Therefore, this study examines the architecture and performance of first-generation Tesla 4680 cells in detail, both by electrical characterization and thermal investigations at cell-level and by disassembling one cell down to the material level including a three-electrode analysis. The cell teardown reveals the complex cell architecture with electrode disks of hexagonal symmetry as well as an electrode winding consisting of a double-sided and homogeneously coated cathode and anode, two separators and no mandrel. A solvent-free anode fabrication and coating process can be derived. Energy-dispersive X-ray spectroscopy as well as differential voltage, incremental capacity and three-electrode analysis confirm a NMC811 cathode and a pure graphite anode without silicon. On cell-level, energy densities of 622.4 Wh/L and 232.5 Wh/kg were determined while characteristic state-of-charge dependencies regarding resistance and impedance behavior are revealed using hybrid pulse power characterization and electrochemical impedance spectroscopy. A comparatively high surface temperature of ∼70 °C is observed when charging at 2C without active cooling. All measurement data of this characterization study are provided as open source.

Data on state-of-the-art battery electric vehicles are crucial to academia; however, these data are not published due to non-disclosure policies in the industry. As a result, simulation models and their analyses are based on assumptions or insider information. To fill this information gap, we present a comprehensive analysis of the electric powertrain of a Tesla Model 3 Standard Range Plus (SR+) from 2020 with lithium iron phosphate (LFP) cells, focusing on the overall range. On the vehicle level, we observe the resulting range in multiple test scenarios, tracing the energy path from source to sink by conducting different test series on the vehicle dynamometer and through alternating current (AC) and direct current (DC) charging measurements. In addition to absolute electric range tests in different operating scenarios and electric and thermal operation strategies on the vehicle level, we analyze the energy density and the power unit’s efficiency on the component level. These tests are performed through procedures on the chassis dynamometer as well as efficiency analysis and electric characterization tests in charge/discharge scenarios. This study includes over 1 GB of attached measurement data on the battery pack and vehicle level from the lab to the real-world environment available as open-source data.

Considering the growing need for extensive energy storage solutions in smart grid technologies and affordable options for entry-level electric vehicles, sodium-ion batteries offer a promising alternative. They use raw materials that are cheaper, less toxic, and more abundant than those used in lithium-ion batteries, making them especially suitable for large-scale applications. This study comprehensively investigated four commercially available sodium-ion batteries to examine their structural and electrochemical characteristics. The cells were dissected, and the electrode dimensions, the areal mass loadings, and the material compositions were analyzed using scanning electron microscopy, energy-dispersive X-ray spectroscopy, powder X-ray diffraction, and attenuated total reflection Fourier-transform infrared spectroscopy. Electrical characterization, including electrochemical impedance spectroscopy, C-rate testing up to 6 C under different ambient temperatures, along with cyclic aging studies, provided insights into the cells’ performance and degradation mechanisms. The findings highlighted variations in electrode coatings, particle sizes, and cathode materials among the cells, which were then correlated with their electrical behavior. This emphasized the challenges in maintaining sodium-ion battery performance, especially at low temperatures. This study was designed to establish a comprehensive knowledge base for both academic and industrial research in sodium-ion battery technology.