--- title: Battery Safety Testing | Fauske & Associates description: Expert Battery Safety Testing solutions and testing services. Ensure safety and compliance with Fauske & Associates' engineering expertise. Learn more. image: https://www.fauske.com/hubfs/hero6.webp --- [![fauske-logo-white](https://www.fauske.com/hs-fs/hubfs/2024-website/branding/fauske-logo-white.png?width=181&height=32&name=fauske-logo-white.png) ](https://www.fauske.com/) Search on Fauske [FAUSKE Line (+1-877-328-7531) ](tel:+18773287531)[ Test Cells & Accessories Store ](https://store.fauske.com/)[ Contact Us ](https://www.fauske.com/contact-us) # Battery Safety Testing As battery technologies advance and energy densities increase, understanding thermal runaway, venting behavior, and flammability risk becomes critical. Fauske & Associates delivers physics-based battery safety testing that goes beyond pass/fail results, providing high-quality experimental data that supports engineering design, hazard mitigation, and regulatory compliance. [ Request a Battery Testing Consultation ](https://www.fauske.com/contact-us) ![hero1](https://www.fauske.com/hubfs/hero1.webp) ![hero2](https://www.fauske.com/hubfs/hero2.webp) ![hero3](https://www.fauske.com/hubfs/hero3.webp) ![hero4](https://www.fauske.com/hubfs/hero4.webp) ![hero5](https://www.fauske.com/hubfs/hero5.webp) ![hero6](https://www.fauske.com/hubfs/hero6.webp) ‹ › ![a look at the interior of a battery cell](https://www.fauske.com/hubfs/battery%20cell.png) Cell ** Cell **   The most basic electrochemical unit, acts as a source of electrical energy by the conversion of chemical energy. Cathode ** Cathode **   The positively charged electrode of a cell, serving as the source of ionic charge carriers for charge accumulation. Electrolyte ** Electrolyte **   A liquid, gel, or solid substance, that facilitates the flow of ionic charge carriers between the anode and the cathode. Separator ** Separator **   A thin, porous material that physically separates the anode and cathode to prevent short circuiting while allowing the movement of ionic charge carriers. Anode ** Anode **   The negatively charged electrode of a cell where ionic charge carriers are stored when charged. Casing ** Casing **   Durable enclosure that protects the cell by containing and insulating the reactive materials within. Positive Terminal ** Positive Terminal **   External electrode through which electrons enter a cell during normal discharge. Negative Terminal ** Negative Terminal **   External electrode through which electrons leave a cell during normal discharge. Safety Device(s) ** Safety Device(s) **   Supplementary built-in safety features, which may include overcharge protection, external short-circuit mitigation, and a safety vent. Click or hover on the colored dots to learn more   ## Cell-Level Battery Safety Testing Cell‑level testing of lithium‑ion and emerging chemistries is conducted to investigate thermal runaway progression and gas generation under a wide range of abuse conditions. These experiments support safety needs across multiple industries—including stationary energy storage, consumer electronics, electric vehicles, industrial systems, and global transportation—through evaluations aligned with relevant standards such as UL9540A (energy storage), UL1642 (consumer use), UL1973 (vehicles), UL62619 (industrial use), and UN 38.3 (transportation). In addition to meeting these established requirements, FAI can also design and perform customized, non‑standard test programs tailored to unique product designs, failure modes, or safety questions. ### Abuse Methods Controlled abuse methods are used to replicate credible failure modes and assess battery behavior under a range of conditions. Testing is performed using adapted adiabatic calorimetry systems that capture high‑resolution thermal and pressure data. Methods include combinations of the following: - **Thermal abuse:** [Flexible polyimide heaters, silicon heaters, custom metal film heaters](https://www.fauske.com/testing/battery-safety#flexible-polyimide-heaters), [standard VSP2 heaters](https://www.fauske.com/testing/battery-safety#standard-vsp2-heaters); direct conduction vs. convective heating - **Electrical abuse:** [External short circuit](https://www.fauske.com/testing/battery-safety#external-short-circuit), forced overcharging, forced discharge - **Mechanical abuse:** [Nail penetration](https://www.fauske.com/testing/battery-safety#nail-penetration), crushing ![slide](https://www.fauske.com/hubfs/slide.png) ![slide2](https://www.fauske.com/hubfs/slide2.png) ![slide3](https://www.fauske.com/hubfs/slide3.png) ![slide4](https://www.fauske.com/hubfs/slide4.jpg) ![slide5](https://www.fauske.com/hubfs/slide5.jpg) ![slide6](https://www.fauske.com/hubfs/slide6.jpg) ![slide72](https://www.fauske.com/hubfs/slide72.jpg) ![slide7](https://www.fauske.com/hubfs/slide7.jpg) ![slide8](https://www.fauske.com/hubfs/slide8.png) ![slide9](https://www.fauske.com/hubfs/slide9.jpg) ![slide10](https://www.fauske.com/hubfs/slide10.png) ![slide11](https://www.fauske.com/hubfs/slide11.gif) ![slide12](https://www.fauske.com/hubfs/slide12.jpg) Vent Sizing Package 2 (VSP2) Advanced Reactive System Screen Tool (ARSST) Preconditioning Equipment and Sample Data Flexible Film Heaters on Various Cell Geometries Custom Metal Film Heater around Cluster of 4 x 21700 Cells Custom Test Can and Placement into Standard VSP2 Heater 18650 Cell Installed in Test Can 4 L Vessel Prior to Closure for Thermal Abuse 70 L Vessel 70 L Vessel Interior External Short Circuit Configuration Nail Penetration Mechanism Installed Nail Penetration Mechanism ‹ › ### [Vent Sizing Package 2 (VSP2)](https://www.fauske.com/testing/battery-safety#vsp2) The VSP2 has been adapted for cell-level testing to provide thermal initiation under adiabatic conditions, enabling detection of self-heating, determination of peak runaway temperature and pressure, and measurement of temperature and pressure rise rates. It also captures venting behavior, including vent temperature, while containing evolved gases for later collection and analysis. Testing can be enhanced through [in-situ preconditioning and voltage monitoring](https://www.fauske.com/testing/battery-safety#preconditioning), interchangeable heater options for coin, cylindrical, and pouch cells, and in-situ video recording. Tests are conducted in either a [70 L vessel](https://www.fauske.com/testing/battery-safety#70L) or a standard [4 L vessel used to contain the “test can.”](https://www.fauske.com/testing/battery-safety#4L) ### [Advanced Reactive System Screening Tool (ARSST)](https://www.fauske.com/testing/battery-safety#arsst) The ARSST has been adapted for thermal abuse testing on smaller cells, including coin cells, with extensions to monitor temperature, pressure, and voltage throughout thermal abuse.   ## Cell Materials of Construction Testing Understanding the behavior of the materials inside a battery is key to designing safer cells. Laboratory-scale tests are conducted to measure how materials react to heat, pressure, and abuse. These tests reveal when materials start to self-heat, how quickly they break down, and whether they release flammable gases. ### Testing Equipment - [Differential Scanning Calorimetry (DSC)](https://www.fauske.com/testing/battery-safety#dsc) - [Thermogravimetric Analysis (TGA)](https://www.fauske.com/testing/battery-safety#tga) - [Accelerating Rate Calorimetry (ARC)](https://www.fauske.com/testing/battery-safety#arc) - [Thermal Activity Monitor (TAM) Testing](https://www.fauske.com/testing/battery-safety#tam)   ![dsc](https://www.fauske.com/hubfs/dsc.webp) ![tga](https://www.fauske.com/hubfs/tga.webp) ![arc2](https://www.fauske.com/hubfs/arc2.webp) ![arc](https://www.fauske.com/hubfs/arc.webp) ![tam](https://www.fauske.com/hubfs/tam.webp) Differential Scanning Calorimeter (DSC) Thermogravimetric Analyzer (TGA) Accelerating Rate Calorimeter (ARC) Accelerating Rate Calorimeter (ARC) Thermal Activity Monitor (TAM) ‹ › ## Gas Analysis & Flammability Testing As lithium-ion cells are heated, they often vent evaporated electrolyte solvents and other potentially flammable gases. Capturing gases both prior to and after thermal runaway enables preparation of bulk mixtures for flammability testing and supports safe system design. ### Capabilities - Gas capture before and after thermal runaway - Identification and quantification of evolved gases (e.g., via GC/MS) - Evaluation of key safety parameters:   - Lower and Upper Flammability Limits (LFL/UFL) - Deflagration index (Kg) - Burning velocity - Deflagration vent sizing - [Testing of flammable liquids and solids](https://www.fauske.com/testing/flammability) ![5L](https://www.fauske.com/hubfs/5L.jpg) 5 L Vessel ## Additional Resources on Battery Testing ## [ Lithium-Ion Battery Scoping Test Using the VSP2 ](https://www.fauske.com/blog/lithium-ion-battery-scoping-test-using-the-vsp2) [Read more ](https://www.fauske.com/blog/lithium-ion-battery-scoping-test-using-the-vsp2) 08.29.23 [![](https://www.fauske.com/hs-fs/hubfs/Screenshot%202023-08-14%20at%203.46.05%20PM.png?width=450&height=337&name=Screenshot%202023-08-14%20at%203.46.05%20PM.png) ](https://www.fauske.com/blog/lithium-ion-battery-scoping-test-using-the-vsp2) ## [ Don't Get Burned by Battery Fires, Test to New UL 9540A Standard ](https://www.fauske.com/blog/dont-get-burned-by-battery-fires) [Read more ](https://www.fauske.com/blog/dont-get-burned-by-battery-fires) 09.11.20 [![Burned iphone from battery fire](https://www.fauske.com/hs-fs/hubfs/8631358891_59a98b9525_b.jpg?width=450&height=337&name=8631358891_59a98b9525_b.jpg) ](https://www.fauske.com/blog/dont-get-burned-by-battery-fires) ### Newsletter Articles: 1. [External Short Circuit Scoping Test of a Lithium-Ion Cell Using the VSP2, Kevin Kunkel, 2024, Volume 31, Issue 4](https://www.fauske.com/hubfs/FAI%202024%20Qtr%204%20Process%20Safety%20News.pdf?hsCtaTracking=590a945f-3ba6-4a88-ab20-e1989e4c6900%7Cad78ab5b-c4cb-4c44-a5e2-7b949889d525) 2. [Process Safety Considerations for Battery Energy Storage Systems (BESS), Emily Ziemba, 2024, Volume 31, Issue 2](https://www.fauske.com/hubfs/FAI%202024%20Qtr%202%20Process%20Safety%20News.pdf?hsCtaTracking=eac16aab-c4e3-4785-b2bb-55df4bf681b8%7Cc4c63cb2-b1be-46ca-9692-e6144dc3491b) 3. [Lithium-Ion Battery Scoping Test Using the VSP2, James P. Burelbach, Kevin Kunkel, Winter 2023, Volume 30, Issue 1](https://www.fauske.com/hubfs/FAI%20Winter%202023%20Process%20Safety%20News-FINAL%202-27.pdf?hsCtaTracking=2c560233-6140-4cc2-9b60-258a8f79110b%7C558eb3b6-e0c8-417f-863e-61a55c41a606) 4. [Don't Get Burned by Battery Fires, Test to New UL 9540A Standard, TJ Frawley, Spring 2020, Volume 27, Issue 2](https://www.fauske.com/hubfs/Process%20Safety%20News%20-%20Spring%202020.pdf?__hstc=41369917.bf9eab8dd69363da3ff1d6d5adece029.1724099130914.1724099130914.1724099130914.1&__hssc=41369917.1.1724099130914&__hsfp=955904189&hsCtaTracking=23e80094-6f4d-4cf5-bd41-abf0f660ab5d%7Cdb6ce9e9-e3fb-46ea-8019-0d1e0a12c2da) 5. [Battery Cell Testing, Ken Kurko, Spring 2009, Volume 16, Issue 2](https://www.fauske.com/hubfs/2009%20Spring%20PSN.pdf) 6. [Closed Cell Test Application for Battery Thermal Stability, Jim Burelbach, Summer 2005, Volume 12, Issue 2](https://www.fauske.com/hubfs/2005%20Summer%20PSN.pdf) ### Papers:  1. [The Versatile VSP2: Battery Testing Kenneth N. Kurko, Kevin L. Kunkel, Philip L. Jackson, Liam T. Horan, Caleb J. Coulthard (Paper GCPS April 6-10, 2025)](https://www.fauske.com/hubfs/GCPS%202025%20-%20The%20Versatile%20VSP2%20-%20Battery%20Testing.pdf) 2. [ARSST Experiments to Evaluate Solvent Compatibility with Stabilized Lithium Metal Powder - James P. Burelbach ECS Transactions, 6 (14) 5-28 (2007) 10.1149/1.2811940, © The Electrochemical Society](https://iopscience.iop.org/article/10.1149/1.2811940) ### Presentations: 1. Fall 2025 P2SAC, West Lafayette, Indiana - The Versatile VSP2: Battery Testing, Liam Horan & Caleb Coulthard (Presenters), 12/3/2025 2. 2025 Spring Meeting and 21st Global Congress on Process Safety, Dallas, TX - The Versatile VSP2: Battery Testing, Presenter: Ken Kurko, April 6-10, 2025 3. 2024 DIERS Fall Meeting, Houston, TX - The Versatile VSP2: Battery Testing, Presenter: Ken Kurko, 10/30/24  #### Contact our team to discuss your battery testing needs and safety requirements. [ Contact Us ](https://www.fauske.com/contact-us)