Fraunhofer EMI develops high-speed X-ray technology for real-time battery analysis

The Fraunhofer Institute for High-Speed Dynamics, Ernst-Mach-Institut (EMI) has developed high-speed X-ray imaging technology designed to observe the internal processes of lithium-ion batteries in real time. Developed in collaboration with PowerCo, Volkswagen’s battery company, this innovation aims to reach industrial application by 2028.

Unlike traditional methods that rely on simulations or destructive testing, this system can capture up to 1,000 images per second. This allows researchers to directly observe dynamic phenomena such as gas formation, material displacement, and crack propagation within large prismatic cells under stress. The diagnostic process utilizes a specialized test chamber equipped with sensors to simultaneously record temperature, pressure, voltage, and gas flow.

A primary focus of the technology is studying thermal runaway, a condition where rapid temperature increases can lead to the expulsion of material and gas. To protect the imaging equipment from extreme test conditions, Fraunhofer EMI created a protective chamber that isolates sensitive X-ray components during severe testing.