Electric vehicle (EV) production in the US has increased exponentially in the past years, and with it comes the need for rigorous EV battery mechanical testing with qualified labs, such as ATS. Mechanical testing helps manufacturers evaluate a battery’s design to create a battery with increased performance, longevity, and safety.
Electric vehicles draw power from rechargeable batteries that power a motor. These batteries can include a variety of materials that impact mechanical properties and reactions:
- Lithium-ion (Li-ion)
- Nickel-metal hydride (NiMH)
- Nickel-cadmium (NiCd)
- Lead-acid
Mechanical Testing Services
Our tests subject a material to life-like forces and conditions until failure, allowing manufacturers to anticipate potential flaws that affect a battery’s reliability, safety, and overall life. We can test for compliance with standards, regulations, original equipment manufacturer (OEM) recommendations, and internal standards for car manufacturer.
Tensile Testing
Tensile testing applies a pulling or stretching force to a material so engineers can determine the material’s tensile strength and elongation. This test helps manufacturers make informed decisions about the appropriateness of a design for its intended use and environment.
The ATS metallurgical lab can combine high temperatures with tensile tests to evaluate a specimen’s material properties under strains and high temperatures. We can test at temperatures as high as 1800˚F. Our mechanical testing equipment can exert a maximum force of 400,000 pounds. The combined testing helps engineers uncover a sample’s characteristics, including:
- Ductility
- Elastic limit
- Elongation and area reduction
- Tensile strength
- Ultimate strength
- Yield strength
Impact Testing
In Charpy testing, a machine strikes a notched specimen at a perpendicular angle with controlled striking energy and stress location for more consistent and reliable measurements. Engineers use Charpy impact testing to determine notch toughness and assess the material’s inherent ductility or brittleness. Our labs can test according to industrial standards and specifications. Popular standards for Charpy impact testing include:
- ASTM E23
- ASTM A370
- ISO 148-1
- ISO 148-2
- ISO 148-3
- EN 10045-1
Compression Testing
Many electric car designs place the battery in the underbody, so the battery must endure the weight of the vehicle frame, furnishings, passengers, and contents. During compression testing, we subject a battery to opposing forces to induce compression until it collapses. This test helps our engineers determine the compressive strength of the materials in a battery. We can test the composites in an EV battery according to standards such as:
- ASTM D3410
- ASTM D695
- ISO 604
- ISO 1856
Vibration Testing
Over time, vibrations can wear down an EV battery and increase the risk of failure. To anticipate an EV battery’s reaction and measure its vibration resistance, we perform vibration testing that introduces the battery to various vibration types and levels. These vibrations can imitate real-life scenarios, such as transit, operation, and installation, and help our experts identify potential flaws.
Our vibration testing lab houses powerful electrodynamic shakers capable of high forces from 6,000 to 12,000 lbf and frequencies from 5 to 2,000 Hz. We can incorporate temperature and humidity control with AGREE chambers to further analyze battery function under complex environmental conditions.
ATS offers vibration testing with various waves:
- Sine
- Random
- Sine on Random
- Random on Random
We can test to standards, including:
- UN 38.3
- IEEE 344
- MIL-STD 810G – Method 514.6, 515.5
- RTCA DO 160 – Section 8
- SAE J1455
- IEC 60068-2-27
- IEC 60068-2-6
- IEC 60068-2-64
About ATS
ATS is a consulting engineering, calibrations, inspections, and testing firm based near Atlanta, Georgia. We offer broad expertise in on-site and laboratory testing for the automotive industry and others, including aerospace, power generation, and manufacturing. We operate multiple labs with ISO/IEC 17025:2017 accreditations to perform IEC/ISO 17025 calibrations and mechanical, electrical, chemical, and nondestructive testing.
Click here for more information on our certifications.
Contact Us
From the lab to the road, effective EV battery designs and ATS battery mechanical testing help drivers get where they need to go safely and reliably. Call +1 (888) 287-5227 to speak with a representative about how our mechanical testing lab can support your EV battery development.
