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Thermal runaway in lithium-ion battery packs poses critical safety challenges in EVs, potentially leading to cascading cell failures and catastrophic fire events. Passive fire protection via intumescent coatings offers a vital secondary defence, swelling on heating to form insulating layers that delays propagation. Industry developments from EV manufacturers highlight the growing focus on lightweight, room-temperature-curing, dielectric coatings for thermal protection. This project leverages and advances these trends, targeting the development of multi-functional coatings to enhance EV battery safety.

This PhD will design and characterise intumescent, dielectric, lightweight, low-cost, and sustainable coatings to arrest cell-to-cell thermal runaway. Experiments will quantify how ceramic-phase nature, morphology, and loading in an epoxy matrix impact key thermal properties (conductivity, heat capacity, flame resistance). Advanced finite element modelling will then correlate microstructural features to heat-transfer performance. The candidate will design and build a burner-rig test apparatus equipped with thermocouples and thermal imaging to simulate realistic runaway events. Top-performing coatings will be validated in situ on live EV cells under controlled runaway conditions.

Dr Francesco Fanicchia is a recognised expert in advanced surface engineering and the development of multifunctional protective coatings, specialising in thermal barriers and fire-resistant materials. As a Senior Lecturer at Cranfield University and Research Area Lead at the Henry Royce Institute, Dr Fanicchia has pioneered innovative epoxy-based intumescent coating systems through the APC-funded CERABEV project, demonstrating their potential in thermal management and protection for battery technologies. This PhD project, building on Dr Fanicchia’s extensive expertise in coating design and thermal protection, will also benefit from collaboration with The Structural Battery Company, a leader in structural battery technology solutions for EV applications, ensuring industry relevance and direct technological impact.

Developing coatings that actively suppress thermal runaway propagation will significantly improve EV pack safety, potentially preventing catastrophic fires and extending evacuation time post-event. The fundamental insight into microstructure–property–performance relationships will guide future sustainable coating formulations. These results support EV manufacturers meeting evolving stringent safety standards and contribute to safer adoption of electrified transport.

Reasons to study:

• Experience in an industry with high prospects of employability. 
• Access to cutting-edge coating design, deposition and characterisation tools, including bespoke burner-rig testing design for realistic thermal testing. 
• Combination of experimental, analytical, and modelling training, ideal for interdisciplinary skill development. 
• Supported opportunity to present at one international conference and engage with EV battery safety stakeholders, including The Structural Battery Company. 
• Builds on proven preliminary results from the Advanced Propulsion Centre (APC)-funded CERABEV project.

The candidate will develop expertise in: 

• Understanding of battery thermal runaway mechanisms and standards. 
• Design and deposition of intumescent coatings.
• Materials characterisation: thermal conductivity, heat capacity, flame resistance. 
• Burner-rig design and thermal imaging methodologies. 
• Microstructural-based finite element modelling of heat transfer in complex materials. 
• Collaboration with industrial partners and communication of safety-critical research.

This multidisciplinary skillset will prepare the candidate for impactful careers in industry (EV vehicle manufacturers, automotive, aerospace, etc.), academia, and EV safety research.