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Ultrasonic testing in battery research and production
Journal article   Peer reviewed

Ultrasonic testing in battery research and production

Sam Amsterdam, Aamani Ponnekanti, Nicolina Nanni, Andrew G. Hsieh, Robin James, Erik D. Huemiller, Daniel A. Steingart and Wesley Chang
Joule, Forthcoming
Mar 2026
DOI: https://doi.org/10.1016/j.joule.2026.102402

Abstract

battery manufacturing non-destructive characterization ultrasound Batteries
This review provides a comprehensive overview of ultrasonic testing (UT) applied to battery research and development, bridging the gap between fundamental acoustic principles and practical applications. We begin by detailing the acoustic physics underlying UT and describing the hardware, software, and signal processing algorithms necessary to extract useful information from battery systems. We then summarize key academic findings and trends in UT analysis of lithium-based batteries, highlighting both foundational studies that have shaped the field and recent advancements pushing the boundaries of UT application. Following this, we provide an overview of lab-scale operando tools that complement UT analysis, illustrating how they can enhance and validate its findings. The discussion is extended beyond academic work to encompass UT applications in battery manufacturing, uniquely incorporating industry perspectives on the challenges and opportunities in this space. Finally, we conclude with a discussion of future directions in battery UT research. This review aims to provide a summary of the current state of UT applied to batteries, equip readers with the tools to contextualize new UT studies and applications, and serve as a practical guide for researchers and engineers seeking to implement UT in their work. [Display omitted] The increased adoption of lithium-based rechargeable batteries requires advanced metrology tools across the entire battery lifecycle. Ultrasound testing (UT) has emerged as a promising, low-cost, and scalable technique for providing valuable insights at various stages of battery development, production, and operation. This review highlights the fundamental principles of UT and its diverse applications, spanning from lab-scale research to manufacturing and field-deployed monitoring. In addition to a synthesis of the existing battery UT literature, including acoustic detection of battery failure modes and decoupling different physical phenomena, we emphasize emerging battery UT methods and applications. For instance, recent advances in ultrasonic transducer technology may be adapted to enhance battery UT resolution. UT techniques could be used not only for battery cell characterization but also for in-line monitoring of slurry quality and electrodes. Lastly, we draw connections from lab-scale research and development to in-line quality assurance and metrology on an industrial scale. Underscoring this is a discussion of current challenges, including signal processing complexity, the need for large datasets, and, especially pertinent to manufacturing and field-deployed applications, cost and throughput. Addressing these issues through methods such as new signal processing techniques, machine learning, and advanced sensors will help drive UT’s adoption of batteries at an industrial scale. This review provides an introduction to ultrasonic testing for battery researchers and an overview of current research directions within the field, covering applications ranging from lab-scale experiments to in-line manufacturing quality control. Perspectives are included from both industry and academia, with an emphasis on the ways ultrasound can complement existing measurement techniques.

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