Thermal Performance Enhancement of a Hybrid Liquid‐Cooled Lithium‐Ion Battery Pack Using Flow Modification and Nanofluid Cooling

ABSTRACT Growing environmental pollution from Internal Combustion engines has driven research toward Electric Vehicles. Lithium‐ion cells, being ideal for Electric vehicles due to their wide operating range and high energy density, require effective temperature regulation through a high‐performance battery thermal management system for their durability and long‐term performance. The current study investigates the cooling performance of BTMS using flow modification in the form of baffles of various shapes in five different BTMS designs (BTMS‐I, II, III, IV, and V), along with their four different inlet/outlet flow configurations (F1, F2, F3, and F4). Additionally the cooling effect of five different nanofluid coolants (TiO 2 ‐Water, Al 2 O 3 ‐Water, SiO 2 ‐Water, ZnO‐Water, and CuO‐Water) at 5% concentration and 0.2 m/s velocity is also studied. The BTMS performance is assessed using three distinct parameters‐maximum temperature ( T max ), maximum temperature difference (∆ T max ) and normalized pumping power (NPP). The findings indicate that TiO 2 ‐Water nanofluid achieves the lowest T max and ∆ T max values of 4.15 K lower than that of water as coolant and among the BTMS designs, BTMS‐II‐F1 exhibits the lowest T max and ∆ T max , equal to 302.07 and 3.93 K, respectively. In addition, the combined effect of optimal BTMS design (BTMS‐II‐F1) and three best‐performing nanofluids (TiO 2 ‐Water, Al 2 O 3 ‐Water, SiO 2 ‐Water) on the T max , ∆ T max , and NPP is studied. The study indicates that the combination of BTMS‐II‐F1 & TiO 2 ‐Water delivers the best cooling performance, with T max , ∆ T max , and NPP values equal to 301.87 K, 3.77 K, and 2.928, respectively. In all cases, the NPP shows an overall increase compared to the base case.