Integrated Risk Analysis and Thermal Runaway Management in Electric Vehicle Lithium-Ion Batteries: A Lifecycle and Safety Engineering Perspective
Keywords:
Lithium-ion batteries, Risk analysis, Battery Management Systems (BMS), Electric Vehicles (EVs), Lithium-ion Batteries, Thermal Runaway, Thermal Management, Lifecycle Safety, EV Battery Safety.Abstract
The increasing use of electric vehicles (EVs) has led to a rapid rise in the use of lithium-ion battery systems because of their high energy density and better performance. However, along with these advantages, battery safety has become a major concern, especially due to thermal runaway, which can lead to fire, explosion, and release of harmful gases. This paper presents a review of risk analysis and thermal runaway management in EV lithium-ion batteries from a lifecycle and safety engineering perspective. The study discusses the main thermal and electrochemical processes responsible for thermal runaway and explains different risk factors associated with battery manufacturing, operation, transportation, storage, and recycling stages. Various risk analysis methods such as Failure Mode and Effects Analysis (FMEA), Fault Tree Analysis (FTA), Bayesian networks, and machine learning-based prediction methods are also discussed. The paper further explains the importance of Battery Management Systems (BMS), thermal management systems, and monitoring techniques in improving battery safety and reliability. The review highlights the need for an integrated safety approach that combines design safety, operational monitoring, thermal management, and lifecycle risk assessment for better prevention of battery failures. The study concludes that multidisciplinary engineering methods and continuous technological improvements are important for safe and reliable large-scale deployment of electric vehicle battery systems
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Copyright (c) 2026 Pranav Gogawale, Samprada Kumar (Author)
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