Numerical Analysis of Heat Transfer Performance of a Battery Pack Hybrid Cooling System Using Cu-Al₂O₃ Hybrid Nanofluid in Aluminium Minichannel and a Phase Change Material

Abstract

A hybrid thermal management system (HTMS) which integrates both active and passive cooling techniques aims to increase heat dissipation, attain uniform temperature and improve battery life. HTMS for lithium-ion batteries is proposed in this paper integrating phase change material (PCM), Cu-Al₂O₃ hybrid nanofluid (HNF) and aluminum minichannels to enhance heat dissipation and temperature regulation under high discharge conditions. Key variables including operating temperature, flow rate, volume concentration of nanoparticles, and cooling medium used in the minichannel are investigated to assess their impact on thermal performance. In this design, the PCM (paraffin wax) acts as a passive cooling element, absorbing and releasing heat to stabilize temperatures, while the cooling medium in the minichannel provides active cooling enhancing convective heat transfer. The combined effects of PCM and cooling medium on reducing maximum temperatures, improving temperature uniformity and managing energy consumption, particularly in electric vehicles and high-power applications are analyzed. It is concluded that HNF consistently provides the lowest battery temperature than single particle nanofluid and water proving its superior heat dissipation capability. Also, HTMS using HNF and PCM is a highly effective thermal management solution for lithium- ion batteries, suitable for electric vehicles and energy storage systems.

Cite as:

Ramesh Krishnan S, Christo Joseph, Nandana S., Nikhil Sam Punnoose, & Noel M Jacob. (2026). Numerical Analysis of Heat Transfer Performance of a Battery Pack Hybrid Cooling System Using Cu-Al₂O₃ Hybrid Nanofluid in Aluminium Minichannel and a Phase Change Material. Journal of Advances in Nanotechnology and Its Applications, 8(1), 31–49. https://doi.org/10.5281/zenodo.19087226