Abstract

This study presents the newly developed “Antriebsbatterie-Inspektion mittels Röntgen” (AIR) system, a 2D X-ray imaging technology designed for radiation-safe scanning of entire vehicles. Utilizing a 360 kV X-ray source, AIR acquires high-resolution images from a bird’s-eye view, allowing for comprehensive inspection of battery packs, including their modules and cells. The aim of this study is to evaluate the mechanical integrity of various battery types, including prismatic, cylindrical, and pouch cells, by examining the visibility of cell and gap deformations. For this purpose, radiographic X-ray images of electric vehicles (EVs) with their built-in traction batteries are examined manually for the visibility and separability of individual cells and intercell gaps. Complementary measurements on reference cells with defined defects demonstrate that AIR can reveal typical mechanical anomalies such as layer misalignment, local deformations, and swelling based on cell and gap visibility.

Keywords: conditions and safety assessment, X-ray inspection, electric vehicles, battery packs, AIR

Materials Evaluation 84 (5): 30–36 | https://doi.org/10.32548/2026.me-04556 | ©2026 American Society for Nondestructive Testing

Introduction