Master Thesis Work - Optimization of Three-Electrode Pouch Cells for Fast-Charging Control

About this opportunity - Background

Fast charging is one of the most important attributes for Battery Electrified Vehicles (BEVs), where there is a constant push to increase charging power and reduce the charging times. The potential risk for the battery cells is, however, significant where an overly aggressive fast charging strategy could cause severe lithium plating on the surface of the cell anode with the consequence of rapid cell ageing or even safety issues. There is therefore a big need to control and optimize fast charging in a way that the customer experiences the shortest possible charging time without risking an increased cell degradation. 

The goal of this thesis project is to establish and optimize an in-house workflow for three-electrode pouch cell assembly and testing. The generated high-quality experimental data will directly support modelling work within the CAE team and contribute to a more physics-based control strategy for fast charging.

Scope of the thesis work

1. Establish an in-house assembly process for pouch cells:

• Conduct the full assembly process inside a glove box to prevent contamination and improve cell consistency.

2. Investigate plating potential variability:

• Quantify and document the variability of anode plating potentials due to assembly differences (welding quality, electrode alignment, electrolyte injection).
• Develop a calibration protocol for each operator to determine the individual plating potential threshold.
• Compare this with the default 0 mV cutoff commonly used in literature.

3. Evaluation of material used for reference electrode:

• Evaluate the feasibility and performance of LTO reference electrodes to extend cell lifetime.
• Formulate a reliable LTO slurry recipe with improved adhesion to copper wire.
• Investigate copper wire surface pre-treatment methods, including ionized washing.

4. Dry cell material assembly with fresh electrolyte:

• Explore whether dry assembly followed by fresh electrolyte injection improves alignment and reproducibility compared to formed cell material from tear downs, especially at low temperatures.

5. Investigate the impact of pouch cell layer configuration:

• Investigate multi-layer pouch cells for improved stability and alignment.
• Monitor internal temperature behavior at high C-rates across various layer configurations

What you'll bring

We are looking for motivated students pursuing a Master of Science degree in chemistry, physics, applied mathematics, or similar, to qualify. A genuine interest and curiosity in the subject matter and excellent analytical and communication skills, both oral and written English, are needed. The ideal candidate has a background in analytical work, preferably including lab-relevant experience. 

Duration

• The duration of the Thesis is 20 weeks.
• The Thesis starts in January 2026 or earlier if possible.
• 30 ECTS (academic credits) if in agreement with your Thesis Advisor at the University.
• This thesis is suitable for 1-2 students