Numerical Investigations on Heat Transfer Characteristics of Mono and Hybrid Nanofluids Using Microchannel Cooling for 21700 Batteries in Electric Vehicles

Efficient thermal management is critical for maintaining the safety, durability, and performance of lithium-ion batteries used in electric vehicles (EVs). In this study, a comprehensive numerical investigation is conducted to evaluate the heat transfer characteristics of mono- and hybrid-nanofluids in a microchannel-cooled lithium-ion battery module. A three-dimensional computational model of a 5S7P battery module composed of cylindrical 21700 cells is developed. Battery heat generation during 3C high discharge rate operation is predicted using the Newman-Tiedemann-Gu-Kim (NTGK) electrochemical model, while coolant flow and heat transfer are simulated using the governing conservation equations for mass, momentum, and energy. The cooling system consists of six liquid-cooling plates with circular microchannels. The performance of water-glycol (50/50) coolant is compared with several mono nanofluids of Al2O3 and Cu, and hybrid nanofluids of Al2O3-Cu, Al2O3-MWCNT, Al2O3-Graphene, Cu-MWCNT, and Cu-Graphene across multiple coolant flow rates from 1–5 LPM. The results demonstrate that nanofluids significantly enhance convective heat transfer and reduce battery temperature compared with the conventional water-glycol coolant. Among the investigated coolants, the Al2O3-Cu hybrid nanofluid (0.45–0.45%) operating at 1 LPM achieves the best overall thermo-hydraulic performance with a performance evaluation criterion (PEC) of 1.065. Further analysis of nanoparticle composition ratios shows that a Cu-dominant hybrid mixture (Al2O3-Cu: 0.27–0.63%) slightly improves the PEC to 1.0657, indicating marginally superior cooling performance. The findings highlight the potential of hybrid nanofluids as advanced coolants for microchannel-based battery thermal management systems in EVs, particularly under moderate coolant flow conditions.