This work presents the first application of three-dimensional digital image correlation for real-time displacement and strain analysis of a pouch type lithium-ion battery. During the electrochemical charge-discharge processes, displacements in the x-, y-and z-directions vary at different states-of-charge (SOCs) attributed to the expansion and the contraction of the interior structure. The z-displacement is observed to develop and concentrate at the vicinity of the openings of the jelly-roll structure. By resolving the displacement components, the progression and distribution of the surface strains, including principal and von-Mises strains, are computed in the charge-discharge processes. It is shown that the dominant strains are up to 0.12 % in the rolling direction of the jelly-roll structure and distribute uniformly on the x-y plane over the surface.

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Cosmetic defects, such as ‘hollows’, are deviations in topology of automotive skin panels that form as a result of springback at the end of the forming process. These deviations are usually too small and local to be detected by discrete measurements of the panel but become visually apparent after the application of paint. As a result, the perceived quality of a panel may become unacceptable and considerable time may be dedicated to minimizing their occurrence through tool modifications. This paper proposes that there are three aspects to the problem. The first is the springback of the panel, the second is the optics of the painted panel, and the third is the ability of human sight to perceive a defect. In particular, it is argued that hollows cause optical distortions that inform the human eye of the presence of a defect. The paper then suggests that signal processing techniques, in particular the wavelet transform, provide a way to relate the geometry of a hollow to the resulting optical distortion. The transform was applied to two physical parts and the paper will discuss the effectiveness of the transform in locating and quantifying the relative severities of the defects that were present.