Rechargeable lithium-ion (Li-ion) batteries are critical in aircraft and aerospace applications due to their high energy density and compact design. However, effective thermal management is essential ..
Rechargeable lithium-ion (Li-ion) batteries are critical in aircraft and aerospace applications due to their high energy density and compact design. However, effective thermal management is essential to mitigate heat generation during charge-discharge cycles, preventing degradation and potential thermal runaway in battery operation. This study investigates the optimization of internal cooling channel geometries within thermal management devices, an area with limited prior exploration. Three channel designs—circular, bent, and curved—are evaluated using computational fluid dynamics (CFD) to assess temperature distribution, velocity, and pressure drop. Binder jetting additive manufacturing is employed to fabricate stainless steel battery case prototypes, which are further analyzed for microhardness and surface roughness. Results indicate that curved channels exhibit superior cooling performance, with an outlet temperature of 17.0°C, a maximum velocity of 20.3 mm/s, and a net heat transfer rate of 1148 W. The final prototype demonstrates an average microhardness of 148 HV and surface roughness of 26 μm, highlighting the feasibility of optimized cooling geometries for enhanced thermal management in Li-ion batteries.
