Coupled Electro-Chemo-Mechanical Degradation in Lithium-Ion Batteries Under Forced Vibration: A Multiphysics Analysis

Lithium-ion batteries in transport applications operate under continuous mechanical vibrations, yet current models typically decouple mechanical stress from electrochemical kinetics. This study quantifies the causal link between forced vibration, solid-electrolyte interphase (SEI) instability, and thermal feedback. Mechanical vibrations applied to the battery surface are transmitted to the particle level via the superposed stress transfer factor. We developed an integrated Multiphysics framework that couples a P2D electrochemical model with comprehensive thermal and structural dynamic behaviour under vibration. A two-stage experimental design (Full Factorial and Central Composite) was utilised to systematically evaluate different vibration amplitudes and frequencies alongside temperature and state of charge (SOC). The model integrates a vibration-induced structural response with electrochemical and thermal processes, thereby directly linking mechanical loading to internal degradation mechanisms under realistic operating conditions. For this purpose, we have integrated battery physics with solid mechanics and fluid heat transfer and performed vibration analysis under a parametric sweep. Results demonstrate that vibration-induced inertial stress accelerates particle fracture, leading to a continuous SEI rupture–reformation cycle that consumes lithium inventory and increases impedance. Discharge profiles reveal an earlier voltage drop, and electrode-level analysis uncovers a distinct SOC asymmetry: vibration suppresses lithiation in the negative electrode while accelerating delithiation in the positive electrode. Crucially, vibration amplitude has a greater impact on capacity fade and resistive heating than frequency, as higher displacement amplitudes drive nonlinear stress accumulation. These findings confirm that static models underestimate degradation, underscoring the necessity of vibration-tolerant electrode designs and electro-chemo-mechanical coupling for accurate lifetime prediction.