Re: Internal Fire Extinguishers
"But seriously, what kind of stresses did they test these batteries for"
Given that only one model of the large range of mobile devices containing this battery technology that Samsung make that has had this sort of issue, I would take a guess that they used industry standard tests that have proved adequate in the past - in the future there may be additional tests. It now seems obvious that many users were doing something different when charging the phones than what the tests expected. It could turn out to be something as simple as leaving the phone turned on when it was being charged - or vice versa. I think it's reasonable to not jump to the conclusion that it was badly manufactured, inadequately tested, batteries, since batteries from both manufacturers exhibited the same problem.
Make no mistake, this could have happened to any cell phone manufacturer (and might well happen to others in the future) - this is no more a Samsung only problem than VW is the only car maker "optimizing" test results.
For the benefit of those whose fingers are hovering over the down vote button, no, I don't work for a cell phone manufacturer, much less Samsung, but I do work with some pretty clever technology in the optics field and am well aware of how long it can take to identify a manufacturing defect in the main product, a software bug or a bought in component fault. My favourite is a software defect that only appears if a specific software release upgrade path was followed - follow any one of several other upgrade paths and the problem never occurs.