Failure Analysis Engineer

Battery Failure Analysis Investigator This role conducts battery failure investigations to identify root causes using analytical testing and laboratory experiments. The position supports testing, operates lab equipment, and collaborates with cross-functional teams to drive corrective actions. Responsibilities also include technical reporting and maintaining a safe, well-managed lab environment. Essential Roles and Responsibilities Failure Analysis Investigations: Lead investigations into battery failures, including cell ruptures, thermal runaway events, capacity fade, and other performance issues, using a combination of analytical techniques and testing methodologies. Conduct thorough examinations of failed battery cells/modules/packs, including visual inspections, non-destructive testing (NDT), and materials analysis, to identify failure modes and mechanisms Root Cause Identification: Analyze data from failure investigations, including voltage/current profiles, temperature measurements, and environmental conditions, to determine the root causes of battery failures. Develop hypotheses and perform root cause analyses to identify contributing factors such as manufacturing defects, design flaws, material degradation, or operational issues. Testing and Validation: Design and execute experiments and tests to validate hypotheses and simulate failure conditions, including accelerated aging tests, thermal cycling tests, and abuse testing (e.g., overcharge, over-discharge).Collaborate with internal and external partners, including research institutions and testing laboratories, to conduct specialized tests and analyses as needed. Laboratory Management: Manage laboratory equipment effectively to maintain an environment conducive to accurate analysis and evaluation Procure laboratory consumables required for battery analysis and manage the disposal of batteries upon completion of testing. Failure Mode Documentation and Reporting: Document findings from failure analyses, including detailed descriptions of failure modes, root causes, and contributing factors, in comprehensive technical reports. Communicate results and recommendations to cross-functional teams, including engineering, quality assurance, and product development, to drive corrective actions and improvements.