Thermite Reaction-Induced Thermal Runaway of Lithium-Ion Batteries

Yuanming Liu; Yao Tian; Zhiqiang Fu; Hongda Du; Baohua Li; Feiyu Kang; Khalil Amine; Guohua Chen

doi:10.1002/adma.202510486

Thermite Reaction-Induced Thermal Runaway of Lithium-Ion Batteries

Yuanming Liu (Co-first Author)
, Yao Tian (Co-first Author)
, Zhiqiang Fu
, Hongda Du
, Baohua Li^*
, Feiyu Kang^*
, Khalil Amine^*
, Guohua Chen^*

^*Corresponding author for this work

School of Energy and Environment

Research output: Journal Publications and Reviews › RGC 21 - Publication in refereed journal › peer-review

9 Citations (Scopus)

Abstract

Safety is a primary concern for the widespread use of lithium-ion batteries (LIBs) in electric vehicles as well as energy storage. Despite the numerous mechanisms proposed to explain thermal runaway (TR) and the various methods implemented to mitigate it, battery explosions still occur. This is predominantly due to an insufficient understanding of the TR mechanism. Herein, by combining various advanced analytical techniques with comprehensive analysis, it is found that aluminum (Al) foil, typically employed as the cathode current collector in LIBs, can react with some cathode active materials to form thermites. These thermite reactions generate substantial heat, contributing to explosions of LIBs, a mechanism that has been largely overlooked. Based on these findings, it is proposed that coating the Al foil with carbon can partially suppress these thermite reactions and substantially enhance the thermal stability of LIBs. This study offers new insights into the TR of LIBs and provides important guidance for developing safer batteries. © 2025 Wiley-VCH GmbH.

Original language	English
Article number	e10486
Number of pages	12
Journal	Advanced Materials
Volume	37
Issue number	43
Online published	14 Aug 2025
DOIs	https://doi.org/10.1002/adma.202510486
Publication status	Published - 29 Oct 2025

Funding

B.H.L. would like to acknowledge the support from the National Natural Science Foundation of China (No. 52261160384, 51872157, 52072208), G.H.C. acknowledges the financial support from the National Natural Science Foundation of China and Research Grants Council of Hong Kong joint research program (N_CityU549/22).

UN SDGs

This output contributes to the following UN Sustainable Development Goals (SDGs)

SDG 7 Affordable and Clean Energy

Research Keywords

lithium battery
mitigation
safety
thermal runaway
thermite reaction

RGC Funding Information

RGC-funded

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10.1002/adma.202510486

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Cite this

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title = "Thermite Reaction-Induced Thermal Runaway of Lithium-Ion Batteries",

abstract = "Safety is a primary concern for the widespread use of lithium-ion batteries (LIBs) in electric vehicles as well as energy storage. Despite the numerous mechanisms proposed to explain thermal runaway (TR) and the various methods implemented to mitigate it, battery explosions still occur. This is predominantly due to an insufficient understanding of the TR mechanism. Herein, by combining various advanced analytical techniques with comprehensive analysis, it is found that aluminum (Al) foil, typically employed as the cathode current collector in LIBs, can react with some cathode active materials to form thermites. These thermite reactions generate substantial heat, contributing to explosions of LIBs, a mechanism that has been largely overlooked. Based on these findings, it is proposed that coating the Al foil with carbon can partially suppress these thermite reactions and substantially enhance the thermal stability of LIBs. This study offers new insights into the TR of LIBs and provides important guidance for developing safer batteries. {\textcopyright} 2025 Wiley-VCH GmbH.",

keywords = "lithium battery, mitigation, safety, thermal runaway, thermite reaction",

author = "Yuanming Liu and Yao Tian and Zhiqiang Fu and Hongda Du and Baohua Li and Feiyu Kang and Khalil Amine and Guohua Chen",

year = "2025",

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day = "29",

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language = "English",

volume = "37",

journal = "Advanced Materials",

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TY - JOUR

T1 - Thermite Reaction-Induced Thermal Runaway of Lithium-Ion Batteries

AU - Liu, Yuanming

AU - Tian, Yao

AU - Fu, Zhiqiang

AU - Du, Hongda

AU - Li, Baohua

AU - Kang, Feiyu

AU - Amine, Khalil

AU - Chen, Guohua

PY - 2025/10/29

Y1 - 2025/10/29

N2 - Safety is a primary concern for the widespread use of lithium-ion batteries (LIBs) in electric vehicles as well as energy storage. Despite the numerous mechanisms proposed to explain thermal runaway (TR) and the various methods implemented to mitigate it, battery explosions still occur. This is predominantly due to an insufficient understanding of the TR mechanism. Herein, by combining various advanced analytical techniques with comprehensive analysis, it is found that aluminum (Al) foil, typically employed as the cathode current collector in LIBs, can react with some cathode active materials to form thermites. These thermite reactions generate substantial heat, contributing to explosions of LIBs, a mechanism that has been largely overlooked. Based on these findings, it is proposed that coating the Al foil with carbon can partially suppress these thermite reactions and substantially enhance the thermal stability of LIBs. This study offers new insights into the TR of LIBs and provides important guidance for developing safer batteries. © 2025 Wiley-VCH GmbH.

AB - Safety is a primary concern for the widespread use of lithium-ion batteries (LIBs) in electric vehicles as well as energy storage. Despite the numerous mechanisms proposed to explain thermal runaway (TR) and the various methods implemented to mitigate it, battery explosions still occur. This is predominantly due to an insufficient understanding of the TR mechanism. Herein, by combining various advanced analytical techniques with comprehensive analysis, it is found that aluminum (Al) foil, typically employed as the cathode current collector in LIBs, can react with some cathode active materials to form thermites. These thermite reactions generate substantial heat, contributing to explosions of LIBs, a mechanism that has been largely overlooked. Based on these findings, it is proposed that coating the Al foil with carbon can partially suppress these thermite reactions and substantially enhance the thermal stability of LIBs. This study offers new insights into the TR of LIBs and provides important guidance for developing safer batteries. © 2025 Wiley-VCH GmbH.

KW - lithium battery

KW - mitigation

KW - safety

KW - thermal runaway

KW - thermite reaction

UR - https://www.webofscience.com/wos/woscc/full-record/WOS:001549345300001

U2 - 10.1002/adma.202510486

DO - 10.1002/adma.202510486

M3 - RGC 21 - Publication in refereed journal

SN - 0935-9648

VL - 37

JO - Advanced Materials

JF - Advanced Materials

IS - 43

M1 - e10486

ER -

Thermite Reaction-Induced Thermal Runaway of Lithium-Ion Batteries

Abstract

Funding

UN SDGs

Research Keywords

RGC Funding Information

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NSFC: Lithium Metal Batteries with Long Life, High Energy Density and High Safety

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Thermite Reaction-Induced Thermal Runaway of Lithium-Ion Batteries

Abstract

Funding

UN SDGs

Research Keywords

RGC Funding Information

Access Output

Other Access Options

Permanent Link

Other Files and Links

Fingerprint

Projects

NSFC: Lithium Metal Batteries with Long Life, High Energy Density and High Safety

Cite this