Cracks In Layer Research Articles

Elucidating effects of form factors on thermal and aging behavior of cylindrical lithium-ion batteries

Cylindrical lithium-ion cells are commercially available in different form factors, e.g., 18650, 21700, 26650, 32700 and 4680. The larger 4680 cells are gaining popularity, especially after the patent filing by Tesla. This paper aims to perform a comparative analysis of the thermal and aging behavior of different form factors using NMC–graphite chemistry during prolonged cycling at moderate operating conditions. A physics-based aging model for lithium-ion batteries is introduced, incorporating side reactions such as solid electrolyte interface (SEI) formation, SEI reformation due to graphite layer cracking, and lithium plating. During cycling, the cell temperature increases with time for all form factors due to internal heat generation. Notably, larger form factor cells experience higher temperatures, attributed to their inferior surface-to-volume ratio for heat dissipation, thereby accelerating both SEI formation and triggering lithium plating in subsequent cycles. This accelerated aging manifests in increased heat generation and prolonged charging for larger cells. The 4680 cell showed the highest rate of capacity loss with a 20% reduction over 480 cycles as compared to the 600 cycles of the 18650 cell. Highlighting accelerated aging in the larger cells due to suboptimal heat dissipation, this study underscores the pressing need for advanced thermal management strategies tailored to the unique challenges posed by larger cells.

Axial compressive properties of GFRP-reinforced PVC-based glued wood-plastic composites column

Wood-plastic composites (WPCs) are environment-friendly materials, which are always used in decoration engineering and outdoor engineering. However, WPCs cannot be directly used as bearing structural members especially columns for their poor tensile and compressive properties and great creep under long-term loading. This study presented an innovative approach of using glass fiber reinforced polymer (GFRP) to reinforce PVC-based glued WPCs short columns. Three effective reinforcement methods were proposed: embedding GFRP bars, wrapping GFRP sheets around the outer surface, and GFRP bars and sheets compound reinforcement. Axial compression tests were conducted to evaluate the load-bearing capacity and deformability of the columns. The results showed that the outer GFRP sheets effectively inhibited the cracking of adhesive layers, leading to a remarkable enhancement in ductility and stiffness of the WPCs columns. Moreover, the ultimate bearing capacity of GFRP bars/sheets compound reinforced columns increased by over 140%. Finite element (FE) analysis was employed to investigate the influence of GFRP reinforcement methods, aiming to obtain the optimal design solution of WPCs columns. A theoretical formula was established to calculate the axial compressive capacity of GFRP-reinforced WPCs columns, and its accuracy was validated through experimental tests and FE modeling.

Effects of human and tectonic activities on groundwater in the upper Yellow River terraces of the loess Plateau

Terraces of the Yellow River are among the most crucial geomorphological landforms pertaining to human survival on the Loess Plateau. After more than half a century of surface flood irrigation, rapid rises in groundwater levels have led to frequent geological disasters, causing a rapid short-term evolution of Yellow River terraces, and an increasingly serious contradiction between this rapid evolution and human survival. However, the process by which water transfers through the thick loess vadose zone and causes a rapid groundwater response within months or years remains controversial. Using the Heitai platform of Yellow River terrace IV as an example, we found, on the basis of regional geological surveys, that at least 112 tectonically-induced cracks have developed in this area. We contend that the superimposed effects of earthquake ground motions from historical and ancient earthquakes since the Late Pleistocene have driven the development of such densely distributed cracks in the loess layer. These cracks, together with a series of fault planes generated by NE-directed extrusive stress at the regional scale, constitute a potential network of preferential channels for water transport within the Heitai platform. Combined with the results of a large-scale in situ ponding test and electrical resistivity tomography, we found that this network of cracks helps to establish catchment areas within the loess layer, thereby increasing soil saturation at a more extensive spatial scale, which may then increase the overall movement velocity of the wetting front. We semi-quantified the efficiency of the crack network in enhancing the recharge of surface water to groundwater, and suggested that the impact of human and tectonic activities substantially shortens the response time of groundwater to surface water, with the reduced time far exceeding one order of magnitude. The results of a field investigation of structural traces and terrace groundwater after the Ms 6.2 Jishishan earthquake on 18 December 2023 further emphasize that a causal mechanism of human and tectonic activities leading to the rapid short-term evolution of groundwater distribution patterns may be universally applicable to all Yellow River terraces on the Loess Plateau. This study mitigates the long-standing controversy concerning the mode of surface water infiltration, including piston flow and preferential flow, and the infiltration medium by which rapid surface water recharge to groundwater occurs in loess areas over short time periods.

Spray-on electronic tattoos with MXene and liquid metal nanocomposites

Electronic tattoos present appealing forms of wearable devices operated directly on the skin. Although two-dimensional transition metal carbides (MXenes) are promising material choices, their films are susceptible to fracturing when subjected to tensile deformations. This study presents electronic tattoos comprising MXenes and liquid metal microcapsules fabricated by spray deposition onto the skin. The resulting nanocomposite has a low sheet resistance of approximately 2.2 Ω/sq. and can be repetitively deformed to 50 % strain. The enhanced deformability is attributed to the release of liquid metal from the microcapsules upon stretching, facilitating the repair of cracks in the nanocomposite layer. In addition, the nanocomposite conforms to the skin, sticks well, and moves with the body. It is also resistant to friction and sweat, making it suitable for various applications. A bifunctional electronic tattoo has been further developed, showcasing its capability to acquire biopotential signals and deliver electrical stimulation. Our study effectively improves the deformability of MXene-based nanocomposites for electronic tattoos, achieving seamless device integration in the body.

Numerical Model for Investigating Effects of Cracks and Perforation on Polymer Electrolyte Fuel Cell Performance

The presence of cracks in the microporous layer (MPL) of polymer electrolyte fuel cells (PEFCs), often occurring during the membrane electrode assembly manufacturing process, has a significant impact on cell performance. However, the exact influence of crack presence, density, and patterns within MPLs on cell performance and transport behaviors remains unclear. This study introduces a three-dimensional macroscale model of PEFCs aimed at investigating the effects of MPL cracks and gas diffusion layer (GDL) perforations on cell performance and transport behavior. This model offers several advantages, including the ability to potentially integrate the effects of flow channel design in future. Additionally, the model can seamlessly incorporate electrochemical reactions and explore phenomena within the catalyst layers (CLs), expanding simulation capabilities beyond water transport alone. The findings suggest that MPL cracks contribute positively to performance by facilitating water drainage. Furthermore, when combined with perforations in GDLs, MPL cracks can significantly enhance performance by providing pathways for water transport. Overall, this study provides valuable insights into developing models for optimizing PEFC performance and underscores the need for further research and development in this area.

Interfacial separation in CRTS Ⅱ type slab track structure subjected to continuous high temperatures: Thermal and moisture effects

To investigate the formation mechanism of cracking in track slab-CA mortar layers under continuous high-temperature conditions, a thermal and moisture coupling deformation theory was used to analyze interlayer damage in ballastless track structures. Firstly, the thermal and moisture coupling deformation and interlayer damage model of the CRTS Ⅱ type slab track structure was established by integrating the thermal and moisture coupling transfer model with the cohesive force damage model through the use of equivalent temperature differentials. The accuracy of the model was verified by setting up an indoor test bench. Secondly, based on the coupled heat and humidity transfer model of the slab-type ballastless track, the distribution characteristics of the temperature and capillary pressure fields were calculated and analyzed using COMSOL Multiphysics® software and the summer meteorological data in Hangzhou, China. The results indicate that the influence depth of drying rapidly developed to 20 mm on day 1, and expanded to 60 mm on day 6; the expansion rate gradually slowed until it reached 120 mm on the 25th day and finally 150 mm on the 40th day. Finally, based on this, the finite element software ABAQUS was used to comparatively analyze the thermal deformation and coupling deformation of both thermal and moisture effects, as well as interlayer damage in the CRTS Ⅱ type slab track structure in the unit state and longitudinal connection state. The results indicate that drying shrinkage can hinder upward arch displacement and damage to the track slab based on the temperature gradient, while significantly worsening upward warping displacement and damage to the track slab. The upward arch displacement decreased by 21.24 % in the unit state and 22.67 % in the longitudinally connected state on the 40th day, while the upward warping displacement increased by 62.17 % and 32.22 %, respectively. Therefore, it is crucial to investigate how moisture deformation impacts the cracking of the track slab-CA mortar layer, as a significant research factor.

Rock fragmentation of simulated transversely isotropic rocks under static expansive loadings

Rock fragmentation is a critical process for mineral extraction and for mitigating overstressed rock in geotechnical applications. In this study, 3D-printed concrete was used to simulate the stratified rock mass, and experimental and numerical methods were employed to investigate crack propagation under static expansive loadings in transversely isotropic rocks. Two types of cracks were observed in the experiments: P-type (a crack propagates primarily along the weak layer) and T-type (a crack propagates across the weak layers) cracks. The findings revealed that the orientation of layers significantly influenced the initiation and propagation of cracks, with P-type cracks commonly observed in simpler P-P mode fragmentations and more complex P-P-T modes emerging under higher expansive loadings. P-T-T modes were characterized by the simultaneous presence of the T-type crack after an initial P-type crack. The AE energy levels in the P-P-T and P-T-T modes were much higher than those in the P-P mode. 2D-DDA models were further built to understand the effects of the loading scales, layer angles, and locations of weak layers on the cracking sequences. The results provided detailed insights into stress evolutions and the impact of expansive loadings on crack initiation and propagation.

An active and durable ammonia cracking layer for direct ammonia protonic ceramic fuel cells

Ammonia protonic ceramic fuel cells (NH3-PCFCs) are highly appealing energy conversion technologies due to their high efficiency, environmental responsibility, and benign safety features. Nonetheless, progress in NH3-PCFCs is notably impeded by the restricted performance and insufficient lifespan of standard Ni-cermet anodes for ammonia cracking, especially at 550 °C or below. Herein, we report an efficient ammonia cracking layer with a formula of xCo3O4/100-xBaZr0.8Y0.2O3-δ (Co/BZY) (x=10, 20, 30), which is deposited onto the Ni-BaZr0.1Ce0.7Y0.1Yb0.1O3−δ (BZCYYb) anode to significantly enhance the NH3 decomposition catalytic activity, thereby improving the performance and durability of NH3-PCFCs at low temperatures. The cells with the addition of a 20Co/80BZY anode catalytic layer (ACL) exhibit low area-specific resistance (ASR) and promising operational longevity under NH3 conditions. At 550°C, the NH3-PCFCs with a 20Co/80BZY ACL exhibit a high peak power density of 0.626 W cm−2 and promising operation durability. This study provides important guidance for constructing high-performance and durable NH3-PCFCs.

Development of craquelure patterns in paintings on canvas

Canvas paintings are layered structures composed of canvas support sized with animal glue, a preparatory layer of the ground, and paint and varnish layers on the top. Preventing or limiting humidity-induced stresses in these structures requires an understanding of the relevant processes and risks. A three-dimensional model of a canvas painting was used to analyse stresses and crack development in the two-layer structure comprised of a glue-sized canvas on a wooden stretcher with a layer of stiff chalk-glue ground representing a pictorial layer in historic canvas paintings. The model was subjected to a large relative humidity fall which induced shrinkage of the glue-sized canvas. The modelling revealed that when a stretcher with flexible wooden bars is considered, high tensile stresses arise in the ground layer at the corners of the painting, and cracks are formed in these areas in the direction perpendicular to the painting’s diagonal. Ratios of critical distances between cracks to the ground layer thickness for which stresses in the midpoints between the cracks dropped to below the level inducing fracture in the material were estimated for various magnitudes of the relative humidity drop and thicknesses of the ground layer. Increasing ground layer thickness limits the hygric response of the sized canvas and makes the paintings less vulnerable to humidity variations. The ratio of stress along the diagonal calculated for painting with one crack to the solution without cracks was described by the double Lorentz function. A simple procedure of calculating stress variations along the diagonal—using the function—on a sequential addition of cracks was developed. Cracks in central parts of canvas painting were found to be induced by permanent cumulative drying shrinkage of the oil-based paints and grounds due to the evolution of the molecular composition of the oil binder. The outcome of the modelling indicated that the risk of cracking of the pictorial layers in canvas paintings due to drops in ambient relative humidity was small.

Liquid Water Transport and Distribution in the Gas Diffusion Layer of a Proton Exchange Membrane Fuel Cell Considering Interfacial Cracks

The proton exchange membrane fuel cell (PEMFC), with a high energy conversion efficiency, has become an important means of hydrogen energy utilization. However, water condensation is unavoidable in the PEMFC because of low operating temperatures. The impact of liquid water on PEMFC performance and stability is significant. The gas diffusion layer (GDL) provides a critical transport path for liquid water in the PEMFC. Liquid water saturation and distribution in the GDL determine water flooding and mass transfer efficiency in the PEMFC. In this study, focusing on the effects of the water introduction method, osmotic pressure, and contact angle, the liquid water transport in the GDL was numerically investigated based on a pore-scale model using the volume of fluid (VOF) method. The results showed that compared with the conventional water introduction method without cracks, the saturation and spatial distribution of water inside the GDL obtained in the simulation were more consistent with the experimental results when the water was introduced through the microporous layer (MPL) crack. It was found that increasing the osmotic pressure resulted in a faster rate of water penetration, faster approaching the steady-state performance, and higher saturation. The ultra-high osmotic pressure contributed to the secondary breakthrough with a significant increase in saturation. Increasing the contact angle caused higher capillary resistance, especially in the region with small pore sizes. At a constant osmotic pressure, as the contact angle increased, the liquid water gradually failed to penetrate into the small pores around the transport path, causing saturation reduction and an ultimate failure to break through the GDL. Increasing the contact angle contributed to a higher breakthrough pressure and secondary breakthrough pressure.

Numerical modelling of bridge deck reinforcement corrosion based on analysis of GPR data

AbstractThis study explores the impact of corrosion on Ground Penetrating Radar (GPR) responses through practical experiments and numerical modelling, focusing on rebar diameter reduction, corrosion product layer thickness, crack formation and corrosion product filling in vertical and transverse crack. Practical experiments involved GPR testing of reinforced concrete slab. By analyzing B-scans we identify areas with moderate and severe corrosion. Numerical modelling using the Finite Difference Time Domain (FDTD) Method to model GPR signal propagation in a concrete bridge deck with corrosion is applied. Key finding includes a significant 26.70% increase in reflected wave amplitude when corrosion product filling in vertical crack increased by 400%, highlighting its extensive effect on signal GPR propagation. Reduced rebar diameter led to a 9.79% amplitude decrease and a 0.06 ns arrival time delay. Increased corrosion product layer thickness primarily affected arrival time with a 0.06 ns extension but significantly amplified GPR signal amplitude. These findings offer insights for improving GPR based corrosion detection and assessment methods, leading to more robust systems for concrete bridge deck inspection and maintenance. This paper contributes to understanding how corrosion affects the signal that is detected by GPR. This information can be used to improve the way that we manage and assess corrosion in concrete bridge deck.

Multiple damage detection in sandwich composite structures with lattice core using regression-based machine learning techniques

The abstract discusses the importance of Structural Health Monitoring (SHM) in ensuring the reliability and health of structures. It introduces a novel approach for recognizing cracks and delamination in sandwich composite structures using advanced methods for data analysis and machine learning algorithms. The research leverages artificial intelligence and machine learning to accurately identify and locate damage such as delamination and cracks in composite sandwich layers, which can significantly enhance troubleshooting performance, improve detection accuracy, and reduce the time and cost associated with repairs. The article presents a damage detection technique utilizing regression analysis for sandwich composite structures with a lattice core, capable of identifying and locating multiple cracks and delamination, as well as simultaneous defects in the structure. The analysis is conducted based on the sandwich composite structure’s healthy and damaged conditions in Abaqus software, and acceleration responses under random forces obtained through the finite element method were used to train various machine learning models, including regression algorithms like k-Nearest Neighborhood Regression (KNN), Light Gradient Boost Machine (LGBM), and Decision Tree Regression (DTR) to detect the damage location. The results indicate that the regression (LGBM), k-Nearest neighborhood, and decision tree regression (DTR) were the most successful functions, respectively, and the damage classification models accurately identified the damage and its location in the composite structure, achieving an accuracy rate of approximately 98.8%.

Comparative study on the effect of chitosan, chitosan nanoparticles, and SiO2 loaded chitosan for the consolidation of the painted stone

The mural paintings are prone to deterioration due to surface powdering, cracking, and loss of painted layers, so coating the mural paintings with eco-friendly benign materials is urgent for consolidation and restoration purposes. Minimizing particle size to the nanoscale results in better properties compared to their bulk equivalents. This paper discussed the utilization of chitosan (Cs), chitosan nanoparticles (CsNPs), and silica-loaded chitosan (SiO2@CsNPs) to improve the consolidation of the painting surfaces on the facade of Neb-Maat-Ra's palace gate, which is a monument to King Ramesses IX (1125–1107 BC) in Egypt. Biopolymers are eco-friendly materials and considered an effective alternatives to synthetic coatings in the consolidation of cultural heritage. Cs has the potential to be a substitute for conserving well-painted paintings and stone, the presence of amino groups in chitosan's structure confers high biological activity and reactivity. CsNPs are more attractive compared to bulk chitosan, moreover, the incorporation of silica (SiO2) into CsNPs created good hydrophilic/hydrophobic balance and enhanced the mechanical scrub resistance. Digital Microscope, Scanning Electron Microscopy (SEM), Portable X-Ray Fluorescence Spectrometer (pXRF), (FTIR ATR), and Colorimetric measurements were used in performing the study. X-ray fluorescence was utilized to determine the compounds used in the facade of Neb-Maat-Ra's palace gate. Limestone served as the support, and hematite was used to create red pigment. The results showed that CsNPs and SiO2@CsNPs were superior to traditional Cs, however, the best result was observed for SiO2@CsNPs. Our study revealed the potential of CsNPs and SiO2@CsNPs in the protection of the facade of Neb-Maat-Ra, the son of King Ramesses.

The Identification of Microstructural Changes in High-Temperature Superconducting Tapes for Superconducting Fault Current Limiters

HTS 2G tapes used in Superconducting Fault Current Limiters (SFCLs) have properties that allow for the effective limitation of short-circuit currents; however, due to the specificity of the device operation, they should be characterized by the high stability of the parameters when repeatedly leaving the superconducting state. During the operation of SFCLs, a situation may occur in which the parameters of the HTS tapes used will change several times as a result of the action of short-circuit currents that exceed the critical current IC of the superconductor of the tape used. This paper presents the results of microstructural tests of 2G HTS tapes intended for SFCLs, subjected to surge currents corresponding to prospective short-circuit currents with values higher than their critical currents IC and for which IC changes were observed. The HTS tapes were examined using a JEOL 7600F field emission scanning electron microscope (SEM), and their chemical composition was analyzed using Energy-Dispersive X-ray Spectroscopy (EDS). The test results indicate the possibility of micro-damage in the form of cracks in the superconductor layer, as well as the interruption of the buffer layers and the oxidation of the silver layers. The analysis of the chemical composition of the HTS tape layers may indicate the occurrence of diffusion processes.

Fatigue life prediction of CFRP flat-fold-flat adhesive joints

Taking the flat-fold-flat (FJF) adhesive joints of carbon fiber reinforced bismaleimide resin-based composite materials as the object, the regularized fatigue life model and residual stiffness model of the one-way plate and the cohesive model parameters of the adhesive layer were fitted experimentally, and based on this, the fatigue life of the adhesive joint was predicted by ABAQUS software. The results show that under specific maximum load conditions, the predicted cracking life of the adhesive layer at the end of the lap joint and the final fatigue life are not greater than the error values of the test results 3% , which has a relatively good calculation accuracy. The cracking life of the adhesive layer at the end of the lap joint is approximately equal to the final fatigue life of the adhesive joint, indicating that the cracking of the adhesive layer at the end of the lap joint accounts for the main part of the total life of the adhesive joint, and the crack propagation life of the adhesive layer can be ignored.

Utilizing cerium as a surrogate for actinide aerosols: Real-time characterization and formation mechanisms in nuclear fire scenarios

Characterizing radioactive aerosol particles released from actinide metals on fires represents a pivotal process in nuclear emergency response. However, the precise characterization of these particles and the deep understanding of their formation mechanism remain a daunting challenge due to the lack of in-situ measurement techniques. We presented the first real-time investigation of respirable particles with the size ranging from 2 nm to 10 μm, emitted from the combustion of cerium metal (CM) as surrogate for actinide counterparts. The evolution of such particles was revealed by the methodology combining scanning mobility particle sizer and optical particle sizer, showing the consistent generation of multimodal ultrafine particles with diameters of 2–100 nm during the combustion reaction. Numerous polydisperse 0.2–0.5 μm accumulated particles and a few 2–10 μm coarse particles were also produced via droplet dispersion and explosion during molten CM self-enhanced combustion. These particles were predominantly composed of CeO2 and exhibited lognormal distributions. The spherical, aggregated, chain-like and fractured particles implied the evolution of particles including nucleation, coagulation, agglomeration and oxide layer cracking. Comparative analyses of particle size distributions reveal that bulk CM combustion predominantly generated ultrafine particles in the absence of CM droplet dispersion. Our finding will guide a critical evaluation of respirable actinide aerosols in the case of fire accidents involving actinide metals.

Corrosion Behavior of 700L Automotive Beam Steel in Marine Atmospheric Environment.

The marine atmospheric corrosion behavior of 700L high-strength automotive beam steel exposed for 36 months was investigated by scanning electron microscopy, energy dispersive spectroscopy, X-ray diffraction, and electrochemical technology. The corrosion kinetics of 700L steel followed the exponential function: D = 4.85t1.23. The rust layers were mainly composited of γ-FeOOH, α-FeOOH, γ-Fe2O3, and Fe3O4, regardless of the exposure duration. With an extended exposure time, the porosity, cracking, and spalling of the rust layers increased, and the densification and thickness uniformity decreased. Electrochemical measurements displayed that the corrosion resistance of the rusted 700L steel gradually decreased with increasing exposure time. A good correlation was found between rust layer composition, microstructure, and corrosion resistance.

Flexural cracking behavior of steel-NC-UHPC composite beam under negative bending moment

Steel-concrete structures are widely applied in bridge engineering due to their superior mechanical performance and cost-effectiveness. However, normal concrete (NC) decks often suffer cracking problems, adversely affecting their serviceability. Ultra-high performance concrete (UHPC) can be used to partially replace the top of NC decks to enhance their post-cracking behavior because UHPC shows high tensile strength, strain-hardening characteristics in tension, and strong bond strength with NC. To this end, this paper focused on the flexural behavior of steel-NC-UHPC composite beams regarding their failure mode, stiffness, strain development, cracking behavior, crack width, etc. Test results indicated that the test specimens mainly exhibited two types of failure modes: shear failure of the NC layer and local buckling of the compressive flange at the steel girder, which were mainly determined by the reinforcement ratio. Flexural stiffness was controlled by the steel girder, and the reinforcement ratio had a notable effect on the reinforcement strain and crack propagation. Additionally, cracks can be categorized into three types: through cracks, connecting cracks, and separate cracks. These cracks in the UHPC layer and NC layer would affect each other, especially those near the roughening interface. The sectional nonlinear analysis was employed to calculate the strain of reinforcement and the steel girder accurately. Finally, the prediction methods of crack width for the NC layer and UHPC layer were discussed. Formulas in NF P18–710 were verified to be feasible for the prediction of UHPC crack width. The UHPC influence factor was introduced to modify the calculation results of the NC crack width by the Chinese NC code.

THz-TDS characterization of stress evolution of EB-PVD TBCs under thermal cycling

The failure of thermal barrier coatings (TBCs) during service is a critical issue affecting aeroengine efficiency. In this study, electron beam physical vapor deposition (EB-PVD) TBCs were subjected to thermal cycling at 1100 °C. Terahertz time-domain spectroscopy (THz-TDS) was employed to characterize the relationship between the evolution of characteristic frequency and the number of thermal cycles, along with the development of stress in the ceramic layer. In situ tensile test revealed a linear correlation between the characteristic frequency and micro strain derived from THz-TDS data, with a proportional coefficient of −9.94 between the characteristic frequency and the slope of the refractive index curve. The results show that the stress evolution can be effectively monitored by recording the trend of characteristic frequency. During the non-failure stage, the characteristic frequency followed a parabolic trend as thermal cycles increased, influenced by the growth of thermally grown oxide (TGO), ceramic layer sintering, and thermal mismatch. Approaching the failure stage, stress evolution was dominated by the expansion of vertical cracks in the ceramic layer and the widening of transverse cracks at the interface, which corresponded to a sudden change in the characteristic frequency.

Study on the Commercial Metalized Plastic Current Collector PET-Cu and PP-Cu Toward High-Energy Lithium-Ion Battery.

Commercial metalized plastic current collector (MPCC) is receiving widespread attention from the business and academic communities, due to its properties of excellent electrical conductivity and low mass density. However, the application of MPCC on the side of copper is rarely studied. Herein, sandwich-like polyethylene terephthalate-based (PET) and polypropylene-based (PP) copper (Cu) current collectors via magnetron sputtering and electroplating are fabricated. Most importantly, the electrical performance, mechanical safety quality, and revealed the corresponding failure mechanism for the MPCC cells are first systematically evaluated. First, during the 45°C electrical cycling tests, PET-Cu CC (82.67%) and PP-Cu CC (82.32%) cells both have comparable capacity retention with the traditional Cu CC (Tra-Cu CC) cell (84.55%) after 500 cycles. The slight reduction in the cycling performance is induced by the crack of the Cu layer around the embedded SiO2 particle for PET-Cu CC cell and the detachment of Cu layer for PP-Cu CC cell. Second, during the nail-penetration test, MPCC cells maintain no fire and explosion for more than 5min, since the heat-shrinkable function of polymeric film can interrupt the continuous Joule heat released by internal short-circuit. This work provides important guidance for the large-scale application of MPCC in the field of lithium-ion batteries.