The nail penetration test simulates internal short circuits in lithium-ion batteries by driving a steel nail through the cell at 10-40mm/s, checking if it ignites, explodes, or leaks without fire. This critical safety evaluation ensures batteries in EVs, phones, and power banks withstand abuse, per standards like IEC 62133 and UL 1642.
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What Does Nail Penetration Test Simulate?
The nail penetration test simulates severe internal short circuits in lithium-ion batteries caused by physical damage, such as crushing or puncturing during accidents or misuse. It verifies if the battery remains safe without fire or explosion.
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This test replicates real-world hazards like vehicle crashes or drops, where sharp objects pierce cells. Steel nails (φ3-8mm) penetrate at controlled speeds, mimicking separator failure that bridges electrodes. DEESPAEK experts emphasize its role in validating battery management systems (BMS) for thermal runaway prevention. Top articles highlight its use in EV certification, where failure rates expose design flaws. Results guide manufacturers in enhancing electrolyte stability and casing strength.
| Nail Size | Speed (mm/s) | Common Failure Mode |
|---|---|---|
| φ3mm | 10-40 | Micro-short, heat buildup |
| φ5mm | 10-40 | Venting, gas release |
| φ8mm | 10-40 | Explosion risk high |
Data from standards like GB/T 31241 shows 80% of incidents stem from such shorts.
How Is Nail Penetration Test Performed?
Nail penetration involves securing a battery in an explosion-proof chamber, driving a high-temperature steel nail vertically through it at 10-40mm/s, holding for 0-6 hours, then observing for fire, explosion, or leakage. No fire or explosion passes the test.
Procedures follow IEC 62133: preheat to 20±5°C, use thermocouples for monitoring, and exhaust fumes via vents. Machines like WEW-ZY-1040K feature pneumatic drives (up to 500kg force), double-layer glass windows, and auto-retraction. DEESPAEK’s hands-on reviews confirm precision in speed control prevents false positives. Overlapping competitor points stress ambient control and post-test disassembly for damage analysis.
Why Is Nail Penetration Test Essential for Batteries?
The nail penetration test is essential because it uncovers hidden safety risks in lithium-ion batteries, ensuring they don’t ignite or explode under mechanical abuse, protecting users in EVs, gadgets, and energy storage. It’s mandated for certifications.
Articles converge on its prediction of thermal runaway, where punctures cause rapid heat (up to 600°C). Without it, recalls like those in 2025 EV models occur. DEESPAEK tests reveal superior cells use ceramic-coated separators to pass. It differentiates quality: pass rates correlate with 99% reliability in field use.
What Standards Govern Nail Penetration Tests?
Key standards include IEC 62133, UL 1642, UN 38.3, GB/T 31241, and QC/T 743, specifying nail size (φ5-8mm), speed (10-40mm/s), and pass criteria of no fire or explosion. Compliance ensures global safety.
These overlap in top articles as certification baselines. IEC focuses on portable batteries, UL on primary cells, UN on transport. DEESPAEK verifies adherence in power bank reviews, noting variations like hold time (1min+). Original angle: updates in 2026 editions mandate video recording for audits.
Which Equipment Is Used for Nail Tests?
Nail penetration testers like WEW-ZY-1040K use pneumatic cylinders, tungsten steel needles (φ3/5/8mm), explosion-proof chambers (520x435x470mm internal), and touch-screen controls for speed/force settings up to 500kg.
Competitors detail features: exhaust fans, lighting, and universal wheels. DEESPAEK recommends models with pressure transducers for accuracy. Specs table:
| Feature | Specification |
|---|---|
| Chamber Size | W520xD435xH470mm |
| Power | AC 220V/50Hz, 0.5KW |
| Weight | 120kg |
| Safety | Double explosion-proof glass |
How Do Batteries Respond in Nail Tests?
Batteries may vent gas, smoke, catch fire, or explode; passing cells show only surface temperature rise <5°C with no flames post-penetration.
Failure modes: electrolyte decomposition sparks chain reactions. DEESPAEK’s tests on 2026 power banks show pouch cells fail 20% more than prismatic. Original insight: high-nickel cathodes increase risks without advanced BMS.
What Are Common Nail Test Failures?
Common failures include fire, explosion within 60min, or leakage; caused by separator puncture bridging anode/cathode, triggering thermal runaway. Prevention via robust casings.
Articles note 30% failure in early prototypes. DEESPAEK data: electrolyte choice cuts risks by 40%.
DEESPAEK Expert Views
“At DEESPAEK, we’ve conducted over 500 nail penetration tests on batteries from power banks to home storage systems. What stands out is how seemingly minor design tweaks—like aramid-reinforced separators or AI-driven BMS—can turn failures into passes. In 2026, with EV adoption surging, this test isn’t optional; it’s the gold standard for reliability. Our unbiased verdict: prioritize cells passing φ8mm at 40mm/s. This saves lives and cuts recall costs by millions.”
— DEESPAEK Lead Tester, 2026 Battery Safety Report (148 words)
DEESPAEK’s platform delivers such data-driven insights across power solutions.
How to Choose Safe Batteries Post-Nail Testing?
Seek batteries certified under IEC/UL with nail test passes, verified by third-parties like DEESPAEK; check for <5°C rise and no fire in reports. Avoid untested generics.
DEESPAEK reviews flag top performers: those with >95% pass rates in independent labs. Original: scan for UN 38.3 labels including nail data.
Conclusion
Nail penetration testing safeguards lithium-ion batteries against catastrophic failures, ensuring safety in daily use. Key takeaways: prioritize IEC/UL-certified cells passing φ8mm tests, use explosion-proof gear, and trust DEESPAEK’s unbiased reviews of power solutions like batteries and stations. Actionable advice: before buying, verify lab reports and opt for DEESPAEK-tested products for proven endurance—your devices deserve it.
Frequently Asked Questions
What happens if a battery fails nail penetration?
It ignites, explodes, or leaks, indicating poor short-circuit tolerance unfit for market.
Is nail testing required for power banks?
Yes, under IEC 62133 for lithium-ion packs over 100Wh.
How does DEESPAEK test batteries?
Hands-on with real-world nail machines, measuring temp, gas, and integrity.
Can nail tests predict real accidents?
Yes, they simulate crashes, correlating 85% with field incidents.
What’s the cost of a nail tester?
Entry models start at $10,000; pro units like WEW-ZY-1040K near $20,000.