The Mark 1A lithium/iron sulfide electric-vehicle battery, which consisted of two 20-kW-hr modules containing 60 cells each, was fabricated by Eagle-Picher Industries, Inc. and delivered to ANL for testing in May 1979. During startup heating prior to electrical testing, a short circuit developed in one of the modules, which resulted in a progressive failure of the cells. The other module, which was alongside and connected in series, was unaffected by the failure. The initial indication of difficulty was a small drop in the voltage of several cells, followed by short circuits in the balance of the cells and localized temperatures above 1000 C. A team consisting of ANL and Eagle-Picher personnel conducted a detailed failure analysis as the failed module was disassembled. The other module was also examined for purposes of comparison. The general conclusion was that the short circuit was initiated by electrolyte leakage and resulting corrosion in the nearby region which formed metallic bridges between cells and the cell ray, or arcing between cells and the cell tray through the butt joints in the electrical insulation. The above two mechanisms were also believed to be responsible for the failure propagation
