Electrification of vehicles intensifies their cooling demands due to the requirements of maintaining electronics/electrical systems below their maximum temperature threshold.In this paper,passive cooling approaches ba...Electrification of vehicles intensifies their cooling demands due to the requirements of maintaining electronics/electrical systems below their maximum temperature threshold.In this paper,passive cooling approaches based on heat pipes have been considered for the thermal management of electric vehicle(EV)traction systems including battery,inverter,and motor.For the battery,a heat pipe base plate is used to provide high heat removal(180 W per module)and better thermal uniformity(<5°C)for the battery modules in a pack while downsizing the liquid cold plate system.In the case of Inverter,two phase cooling system based on heat pipes was designed to handle hot spots arising from high heat flux(∼100 W/cm2)–for liquid cooling and provide location independence and a dedicated cooling approach-for air cooling.For EV motors,heat pipebased systems are explored for stator and rotor cooling.The paper also provides a glimpse of development on high-performance microchannel-based cold plate technologies based on parallel fins and multi-layer 3D stacked structures.Specifically,this work extends the concept of hybridization of two-phase technology based on heat pipes with single-phase technology,predominately based on liquid cooling,to extend performance,functionalities,and operational regime of cooling solutions for components of EV drive trains.In summary,heat pipes will help to improve and extend the overall reliability,performance,and safety of air and liquid cooling systems in electric vehicles.展开更多
In this study, cold spraying（CS） was used to deposit a mixture of nickel-coated graphite and 40 vol.% Al powder（Ni-Gr/Al） on a steel substrate aiming to effectively preserve a certain volume fraction of graphite i...In this study, cold spraying（CS） was used to deposit a mixture of nickel-coated graphite and 40 vol.% Al powder（Ni-Gr/Al） on a steel substrate aiming to effectively preserve a certain volume fraction of graphite in the deposited Ni-Gr/Al composite coating. The microstructure of the as-sprayed coating and the effect of post-spray heat-treatment（PSHT） temperatures on the in-situ formation of Ni-Al intermetallic phases in coating were studied. The tribological behaviors of the as-sprayed coating and the PSHTed coating under 450？C were tested at 25？C, while the as-sprayed coating was tested at 450？C for comparison.As a result, the Ni-Gr particles showed a homogenous distribution in the coating. The multilayer Ni-Al intermetallics-coated graphite/Al composite coating was achieved in situ after the PSHT of 450？C, where the graphite did decompose at 550？C leaving big pores in the coating. The coefficients of friction（COF）of the CSed coating and the PSHTed coating were measured at 450？C as well as 25？C, which showed a similar tendency, much higher than that of the CSed coating tested at 25？C. The lubrication phase（graphite） improved the formation of a graphite film during sliding friction and decreased the COF, while the hard Ni-Al intermetallic phases contributed to the increase of COF.展开更多
文摘Electrification of vehicles intensifies their cooling demands due to the requirements of maintaining electronics/electrical systems below their maximum temperature threshold.In this paper,passive cooling approaches based on heat pipes have been considered for the thermal management of electric vehicle(EV)traction systems including battery,inverter,and motor.For the battery,a heat pipe base plate is used to provide high heat removal(180 W per module)and better thermal uniformity(<5°C)for the battery modules in a pack while downsizing the liquid cold plate system.In the case of Inverter,two phase cooling system based on heat pipes was designed to handle hot spots arising from high heat flux(∼100 W/cm2)–for liquid cooling and provide location independence and a dedicated cooling approach-for air cooling.For EV motors,heat pipebased systems are explored for stator and rotor cooling.The paper also provides a glimpse of development on high-performance microchannel-based cold plate technologies based on parallel fins and multi-layer 3D stacked structures.Specifically,this work extends the concept of hybridization of two-phase technology based on heat pipes with single-phase technology,predominately based on liquid cooling,to extend performance,functionalities,and operational regime of cooling solutions for components of EV drive trains.In summary,heat pipes will help to improve and extend the overall reliability,performance,and safety of air and liquid cooling systems in electric vehicles.
基金financial support from the program of China Scholarship Council (No. 201404490058)Marie-Curie (No. 268696)+2 种基金the National Key Research and Development Program of China (No. 2016YFE0701203)the National Natural Science Foundation of China (No. 51574196)the 111 Project (No. B08040)
文摘In this study, cold spraying（CS） was used to deposit a mixture of nickel-coated graphite and 40 vol.% Al powder（Ni-Gr/Al） on a steel substrate aiming to effectively preserve a certain volume fraction of graphite in the deposited Ni-Gr/Al composite coating. The microstructure of the as-sprayed coating and the effect of post-spray heat-treatment（PSHT） temperatures on the in-situ formation of Ni-Al intermetallic phases in coating were studied. The tribological behaviors of the as-sprayed coating and the PSHTed coating under 450？C were tested at 25？C, while the as-sprayed coating was tested at 450？C for comparison.As a result, the Ni-Gr particles showed a homogenous distribution in the coating. The multilayer Ni-Al intermetallics-coated graphite/Al composite coating was achieved in situ after the PSHT of 450？C, where the graphite did decompose at 550？C leaving big pores in the coating. The coefficients of friction（COF）of the CSed coating and the PSHTed coating were measured at 450？C as well as 25？C, which showed a similar tendency, much higher than that of the CSed coating tested at 25？C. The lubrication phase（graphite） improved the formation of a graphite film during sliding friction and decreased the COF, while the hard Ni-Al intermetallic phases contributed to the increase of COF.
