AZL Aachen GmbH has launched a new Joint Partner Project titled “Thermal Runaway Testing for Battery Casings – Benchmarking Systems for High-Gradient Heating and Hot Particle Blasting.” The initiative addresses a growing challenge in electric vehicle (EV) development: the need for reliable, real-world fire testing methods that evaluate how structural and functional materials perform under conditions of thermal runaway.
As battery systems become more powerful and energy-dense, thermal management and fire protection are becoming critical factors in EV safety design.
This project aims to establish a reproducible testing environment that simulates the extreme conditions of thermal runaway events, particularly those associated with lithium-ion chemistries, such as LFP and NMC. It combines high-gradient flame exposure with targeted hot particle impact.
The result is a test bench that more accurately reflects the stress scenarios faced by EV battery housings in the field.
The project is designed for direct relevance to automotive OEMs, Tier 1 suppliers, and material developers seeking to validate next-generation battery enclosures. Participating companies will not only gain access to benchmarking results but can also contribute their material configurations for testing.
Evaluations will compare thermal resistance and mechanical integrity across a range of realistic profiles, supported by comprehensive documentation, thermal data, and high-resolution video. The outcome is a robust matrix that supports product development, qualification, and supplier comparison.
This effort builds on a previous AZL collaboration involving 24 industry players, including Audi, BMW, and major Tier suppliers that co-developed a flame-exposure test method that simultaneously measured mechanical performance under thermal load. More than 50 material systems were benchmarked in that project, including metals, polymers, fiber-reinforced composites, coatings, and sandwich constructions.
The new Joint Partner Project leverages this foundation to create a more advanced, application-specific benchmarking process tailored to the unique thermal risks of EV battery design. While the primary focus is e-mobility, the testing infrastructure is also applicable to aerospace and other industries requiring safe, compact energy storage.
With over a decade of experience managing collaborative R&D, AZL provides a structured, transparent process that enables partners to pool expertise, reduce development risks, and gain insight into alternatives on the market.
Filed Under: Technology News, Thermal Management