In response to the growing importance of thermal management and fire protection in electromobility, AZL Aachen GmbH is launching a new joint partner project entitled “Thermal Runaway Testing for Battery Casings – Benchmarking Systems for High-Gradient Heating and Hot Particle Blasting”. This initiative focuses on the development and implementation of a realistic and repeatable fire test for testing and comparing structural and functional materials used in EV battery casing systems.
Advanced test infrastructure for real-life conditions
The project focuses on the development and implementation of a new test bench that combines high-temperature flame treatment and controlled particle bombardment to mimic the complex conditions of a thermal runaway in modern cell technologies such as LFP and NMC. This setup enables systematic benchmarking of materials under stress conditions that correspond to applications in the automotive industry, but also in other segments such as aerospace, where efficient development of safe battery storage systems is essential. Participating companies will not only have access to the final benchmarking results, but will also be able to contribute material configurations for testing within the project.
Benchmarking of materials and definition of safety profiles
Customized test profiles are used to compare the thermal resistance and mechanical integrity of different materials based on application-specific scenarios. Detailed test documentation, including videos and thermal data, is provided. The resulting matrix supports material development, qualification and supplier evaluation and provides both a strategic and technical advantage.
A collaborative approach to a common challenge
As part of a previous project involving a consortium of 24 leading industrial companies (including car manufacturers such as Audi and BMW, tier suppliers and material manufacturers), the AZL team of experts developed an application-related metrological test method that enables materials to be tested at different flame temperatures and the material strength to be measured simultaneously under fire load. As part of the project, more than 50 different materials (metals, plastics, fiber-reinforced, coated, compact and sandwich materials) were tested and evaluated with regard to their specific performance (survival under tensile load and flame exposure at 800, 1000 and 1200 °C; failure; weight per unit area; cost per unit area). The new Joint Partner Project builds on these results, the know-how and the implemented test infrastructure. It enables the participants to pool their resources, validate their own solutions and gain insights into leading alternatives on the market. With more than ten years of experience in organizing cooperative industry projects, AZL ensures professional and transparent implementation with clear, practical results. The project will officially kick off on July 15, 2025, when the partners will meet for the first time to align their expectations, present their priorities and determine the focus of the tests. Companies interested in participating are invited to request detailed project information or schedule an individual consultation:
Contact
Philipp Fröhlig
Head of Industrial Services
Email: philipp.froehlig@azl-aachen-gmbh.de
Phone: +49 241 475 735 14