Battery Thermal Runaway Test Service

Battery Thermal Runaway Test Service – Accredited ISO/IEC 17025 Safety and Performance Assessment for the Colombian Market

Battery thermal runaway is a critical safety concern for lithium-ion and other rechargeable battery technologies used in consumer electronics, electric vehicles (EVs), energy storage systems (ESS), medical devices, power tools, and aerospace applications. Thermal runaway is a chain reaction of exothermic reactions within the cell that leads to a rapid increase in temperature, pressure, and the release of flammable gases, often resulting in fire, explosion, and significant damage. In the Colombian market, where the Superintendencia de Industria y Comercio (SIC), the Ministerio de Minas y Energía (MinMinas), the Unidad de Planeación Minero Energética (UPME), and the Dirección de Impuestos y Aduanas Nacionales (DIAN) are increasingly enforcing stringent safety and quality standards for battery-powered products and energy storage systems, the accurate evaluation of thermal runaway behavior is essential for product certification, supplier qualification, quality control, and import-export processes. Our laboratory offers a comprehensive battery thermal runaway test service, applying standardized methods to evaluate the initiation, propagation, and effects of thermal runaway under controlled and reproducible conditions. All tests are performed under our ISO/IEC 17025 (CNAS) accreditation, and the resulting reports are fully accepted by Colombian authorities, making them indispensable for regulatory compliance, product validation, and market access in Colombia.

Battery Test Samples We Regularly Examine

Our laboratory receives a wide variety of battery cells, modules, and packs for thermal runaway testing. Typical samples include:

• Lithium-ion cylindrical cells – 18650, 21700, 26650, and other standard sizes.
• Lithium-ion prismatic cells – of various capacities and chemistries (LCO, NMC, LFP, LTO).
• Lithium-ion pouch cells – used in consumer electronics, automotive, and medical devices.
• Battery modules and subpacks – for electric vehicles, e-bikes, and ESS.
• Battery packs – complete assemblies with battery management systems (BMS), interconnects, and housings.
• Prototype and new battery designs – submitted by manufacturers for validation of thermal runaway resistance before series production.
• Batteries retrieved from field service – for failure analysis and assessment of thermal runaway risk after aging.

Abuse Testing – Inducing Thermal Runaway under Controlled Conditions

To evaluate thermal runaway behavior, the battery is subjected to controlled abuse conditions that simulate internal short circuits, overcharging, external heating, mechanical deformation, or other failure scenarios. Our tests follow international standards and the requirements of the Colombian energy and transportation sectors.

• Overcharge test (IEC 62660-2 / UL 1642 / NTC 6700) – the battery is charged at a constant current (typically 1C to 3C) until the voltage reaches a specified limit (e.g., 2 × the maximum charging voltage) or until thermal runaway is observed. The test is performed at 20 °C and 45 °C. We monitor the cell voltage, temperature, and current during the overcharge, and we record the time to thermal runaway, the maximum temperature reached, and the pressure increase inside the test chamber. We report the overcharge voltage, the current, the time to runaway, and the maximum temperature.
• External short circuit test (IEC 62660-2 / UL 1642 / NTC 6701) – the battery terminals are short-circuited using a low-resistance connection (typically < 50 mΩ) for a specified duration (e.g., 10 minutes) or until the cell temperature reaches a maximum. The test is performed at 20 °C and 45 °C. We measure the cell temperature, voltage, and current during the short circuit. We report the short-circuit current, the temperature rise, and any signs of venting or rupture.
• External heating test (oven exposure) – IEC 62660-2 / UL 1642 / NTC 6702 – the battery is placed in an oven and heated at a controlled rate (typically 5 °C/min to 10 °C/min) until the temperature reaches a specified setpoint (e.g., 200 °C, 250 °C) or until thermal runaway occurs. The temperature of the cell, the oven, and the ambient are monitored. We report the heating rate, the temperature at which thermal runaway initiates (onset temperature), and the maximum temperature reached during the event.
• Penetration test (nail penetration) – IEC 62660-2 / UL 1642 / NTC 6703 – a steel nail (typically 3 mm to 6 mm diameter) is driven into the battery cell at a controlled speed (e.g., 10 mm/s to 50 mm/s) to simulate an internal short circuit. The test is performed at 20 °C. We monitor the cell voltage, temperature, and the force applied. We report the penetration depth, the force profile, the cell voltage drop, and the temperature evolution.
• Crush test (mechanical deformation) – IEC 62660-2 / UL 1642 / NTC 6704 – the battery is compressed between two flat plates until a specified force (e.g., 100 kN) or a specified compression (e.g., 10 % of the cell width) is reached, or until thermal runaway is observed. We report the crushing force, the displacement, and the cell's response (e.g., short circuit, venting, thermal runaway).
• Drop test (mechanical shock) – IEC 62660-2 / UL 1642 / NTC 6705 – the battery is dropped from a specified height (e.g., 1.0 m, 1.5 m) onto a hard surface (concrete or steel) to simulate accidental drops. The test is performed in multiple orientations (e.g., face, edge, corner). We report the drop height, the orientation, and the condition of the battery after the drop.

Thermal Runaway Propagation Test – Evaluating Cell-to-Cell Propagation

In battery modules and packs, thermal runaway can propagate from one cell to neighboring cells, leading to a cascading failure. Our propagation tests evaluate the ability of a battery module or pack to prevent the spread of thermal runaway, which is critical for the safety of large-scale energy storage systems and electric vehicles. These tests follow international standards and the guidelines of the MinMinas and UPME for safe energy storage.

• Propagation test in module (IEC 62619 / UL 9540A / NTC 6710) – a battery module or pack is subjected to a thermal runaway initiation event in one cell (e.g., by nail penetration, overcharge, or external heating). The propagation of thermal runaway to adjacent cells is monitored using thermocouples, voltage sensors, and gas detectors. We record the temperature of each cell, the time of propagation, and the number of cells affected. We report the propagation rate (cells per second), the maximum temperature, and the total number of cells involved in the propagation event. The test is performed in a fire-resistant chamber equipped with a ventilation system.
• Propagation test at different temperatures (NTC 6711 – thermal effects on propagation) – the propagation test is performed at 23 °C, 45 °C, and 60 °C to evaluate the effect of ambient temperature on the spread of thermal runaway. We report the propagation behavior at each temperature.
• Propagation test with different battery configurations (NTC 6712 – cell spacing and arrangement) – the test is performed with different cell spacings and arrangements (e.g., 1 mm, 5 mm, 10 mm gap) to evaluate the effect of thermal insulation and heat dissipation on propagation. We report the propagation outcome for each configuration.
• Propagation test with active cooling (NTC 6713 – effect of cooling systems) – the test is performed on a battery module with and without active cooling (e.g., fans, liquid cooling) to evaluate the effectiveness of the cooling system in preventing propagation. We report the propagation with and without cooling.
• Propagation test with enclosure and barriers (NTC 6714 – effect of module enclosure) – the test is performed on a module with and without a fire-resistant enclosure and thermal barriers, to evaluate the effectiveness of the module design in containing thermal runaway. We report the propagation and the extent of damage to the enclosure.

Venting and Gas Analysis – Characterizing the Emissions during Thermal Runaway

During thermal runaway, batteries release large volumes of flammable and toxic gases, including hydrogen, carbon monoxide, hydrocarbons, and hydrogen fluoride. Our gas analysis characterizes the composition and quantity of these emissions, which is essential for designing ventilation and fire suppression systems and for assessing the risks to personnel and the environment. These tests are required for the certification of battery safety in the Colombian mining, manufacturing, and energy sectors.

• Gas sampling during thermal runaway (NTC 6720 – gas collection and analysis by GC-MS) – during the thermal runaway event, the gases released from the cell or module are collected into gas sampling bags or canisters. The gas composition is analyzed using gas chromatography with mass spectrometry (GC-MS) and flame ionization detection (FID). We measure the concentrations of hydrogen (H₂), carbon monoxide (CO), methane (CH₄), ethylene (C₂H₄), hydrogen fluoride (HF), and other hydrocarbons. We report the gas composition (in vol% or ppm) and the total volume of gas released (in liters).
• Differential scanning calorimetry (DSC) for thermal stability (ASTM D3418 / NTC 6721) – we perform DSC on the cell components (anode, cathode, electrolyte) to determine the onset temperature of exothermic reactions, the heat generated, and the activation energy of the decomposition reactions. We report the onset temperature, the peak temperature, and the heat of reaction (J/g).
• Accelerating rate calorimetry (ARC) – ASTM E1981 / NTC 6722 – we use an ARC instrument to measure the self-heating rate of the battery under adiabatic conditions, which allows us to determine the self-heating rate and the thermal runaway onset temperature and the heat generation rate. We report the self-heating rate and the thermal runaway onset temperature.
• Pressure and temperature measurement during thermal runaway (NTC 6723 – real-time monitoring) – during the thermal runaway test, we use pressure transducers and thermocouples to measure the pressure and temperature inside the test chamber. We report the maximum pressure (in kPa), the pressure rise rate (in kPa/s), and the maximum temperature (in °C).
• Fire and combustion behavior (NTC 6724 – flame propagation and heat flux) – for battery packs that ignite, we measure the flame height, the heat flux (in kW/m²) at a specified distance, and the burn duration. We report the flame characteristics and the heat flux data.

Safety Systems and Mitigation Testing – Evaluating Protection and Containment

To ensure the safety of battery systems, we test the effectiveness of safety systems such as pressure relief vents, thermal fuses, battery management systems (BMS), fire suppression systems, and enclosures. These tests are essential for the certification of battery packs used in electric vehicles, storage systems, and critical equipment in the Colombian market.

• Vent and burst disk activation test (NTC 6730 – pressure relief performance) – during the thermal runaway event, we record the pressure at which the vent or burst disk activates, and we measure the amount of gas released through the vent. We report the activation pressure, the venting efficiency, and the integrity of the vent.
• BMS response test (NTC 6731 – protective shutdown under abuse) – we test the BMS response to overcharge, over-discharge, over-temperature, and external short circuit. We verify that the BMS triggers a protective shutdown (e.g., by opening the contactor) before thermal runaway occurs. We report the trigger conditions and the response time of the BMS.
• Fire suppression system test (NTC 6732 – effectiveness of extinguishers) – for battery enclosures with fire suppression systems, we initiate a thermal runaway event and measure the time required for the suppression system to extinguish the fire, and the residual heat and gas release. We report the extinguishing time, the temperature drop after suppression, and the effectiveness of the system.
• Enclosure integrity test (NTC 6733 – mechanical containment of fire and gas) – after a thermal runaway event, we inspect the battery enclosure for cracks, deformation, or openings that could allow the escape of flame, smoke, or hot gases. We report the condition of the enclosure and any signs of failure.
• Thermal barrier test (NTC 6734 – effectiveness of insulation between cells) – we test the thermal barrier between two cells by applying a thermal pulse to one cell and measuring the temperature rise in the adjacent cell. We report the temperature reduction provided by the barrier, and the barrier integrity after the test.

Complementary Tests – Material Characterization, Post-Test Inspection, and Forensic Analysis

To fully understand the thermal runaway mechanism and to identify the root cause of battery failure, we perform post-test visual inspection, material characterization, and forensic analysis. These analyses are essential for determining the failure mode (e.g., internal short, overcharge-induced lithium plating, manufacturing defect) and for developing mitigation strategies. They are also required for safety investigations by the SIC and MinMinas.

• Post-test visual inspection (NTC 6740 – disassembly and examination) – the battery is disassembled after thermal runaway, and the internal components (anode, cathode, separator, current collectors) are visually inspected for damage, melting, short circuits, and lithium plating. We report the condition of each internal component.
• Scanning electron microscopy (SEM) and EDS analysis (ASTM E1508 / NTC 6741) – we examine the electrode materials, separator, and current collectors using SEM to identify the morphology of the damage, dendrites, melted areas, and other microstructural changes. EDS is used to analyze the composition of the deposits on the electrodes. We report the SEM images and the chemical composition of the deposits.
• X-ray diffraction (XRD) analysis (NTC 6742 – for material phase identification) – we analyze the cathode and anode materials to detect phase transformations, the formation of unwanted phases (e.g., Li₂CO₃, LiF), and the loss of active material, which may have contributed to the thermal runaway. We report the XRD patterns and the identified phases.
• Thermogravimetric analysis (TGA) of the separator and electrolyte (ASTM E1131 / NTC 6743) – we measure the thermal stability of the separator and the electrolyte to determine their decomposition temperatures and their contribution to the thermal runaway event. We report the decomposition temperature, the mass loss, and the heat of reaction.
• Internal short circuit analysis (NTC 6744 – detection of metal deposits, dendrites, and defects) – we examine the separator for signs of perforation, dendrite growth, and the presence of metal particles that could have caused an internal short circuit. We report the findings and the likely cause of the short circuit.
• X-ray CT and radiography of the failed cell (NTC 6745 – non-destructive imaging) – for a detailed, non-destructive assessment of the internal damage, we perform X-ray computed tomography (CT) or radiographic imaging of the post-test battery. The CT scan reveals the internal structure, the distribution of melted areas, and the location of short circuits. We report the CT images and the interpretation of the damage.

Test Report and Recognition in the Colombian Energy, Automotive, and Industrial Sectors

All procedures described are within the scope of our ISO/IEC 17025 accreditation, with equipment calibrated periodically (ovens, short-circuit testers, nail penetrators, gas analyzers, DSC, TGA, etc.) and traceability to international standards (NIST, PTB). Our test reports are issued in Spanish and include:

• Full identification of the battery sample (manufacturer, model, chemistry, capacity, voltage, lot number, and date of manufacture).
• Detailed description of the test methods applied (IEC/UL/ASTM/NTC standards, abuse conditions, temperatures, rates, and environmental conditions).
• Numerical results: thermal runaway onset temperature (°C), maximum temperature (°C), maximum pressure (kPa), propagation time (s), gas composition (vol%), heat flux (kW/m²), and failure mode.
• Graphical data: temperature vs. time curves, voltage vs. time curves, pressure vs. time curves, and DSC/ARC thermograms.
• Comparative tables against the values specified by the client or against the limits of the IEC 62660-2, UL 1642, NTC 6700, and the requirements of the SIC, MinMinas, UPME, and DIAN for battery safety and performance.
• Photographs and micrographs (SEM, CT, X-ray) of the battery before and after testing, showing the extent of damage, melting, and any internal defects.
• Recommendations for design improvement (e.g., enhanced thermal management, improved separator materials, addition of fire barriers, and BMS updates) and for safe handling, storage, and transport.
• Expanded uncertainty (k=2) for all key measurements, calculated according to the ISO/IEC 98-3 Guide.

These reports are fully accepted by the Superintendencia de Industria y Comercio (SIC) for product registration and quality certification, by the Ministerio de Minas y Energía (MinMinas) and the Unidad de Planeación Minero Energética (UPME) for the validation of batteries used in energy storage and power generation projects, and by the Dirección de Impuestos y Aduanas Nacionales (DIAN) for tariff classification and quality verification in the import of batteries and battery-powered equipment. Additionally, we offer consulting services for the design of safe battery systems, the selection of appropriate safety devices (e.g., vents, fuses, BMS), and the implementation of fire suppression and thermal management solutions, contributing to the safety, reliability, and sustainability of energy storage and electric mobility in the diverse and growing Colombian market, from the Amazon rainforest to the Andean highlands and the Caribbean coast.