Copper Wire Resistance Corrosion Test for Assessing Copper Compatibility of E-Thermal Fluids for Battery Electric Vehicles (BEVs)

Author:

Tormos Bernardo1ORCID,Ruiz Santiago1ORCID,Alvis-Sanchez Jorge1ORCID,Farfan-Cabrera Leonardo Israel2ORCID

Affiliation:

1. Clean Mobility & Thermofluids, Universitat Politècnica de València, 46022 Valencia, Spain

2. Escuela de Ingeniería y Ciencias, Tecnologico de Monterrey, Monterrey 64849, Mexico

Abstract

This study aims to assess the compatibility of various e-thermal fluids for immersion cooling in battery electric vehicles through a copper wire resistance corrosion test. The tested fluids include a polyalphaolefin, diester, mineral oil API G-III, transformer oil, and a fully formulated dielectric coolant. The test was conducted at 130 °C for 336 h, and the resistance of the copper wires was monitored in vapor and oil phases. By comparing the resistance variation and analyzing portions of the wires through scanning electron microscopy, it was found that the vapor phase of PAO and diester in one of the tests exhibited significant corrosion, while the dielectric coolant showed minimal corrosive effects, implying better compatibility. These results provide insights into the corrosion behavior and compatibility of the fluids with copper, which are essential for selecting suitable dielectric fluids for immersion cooling applications in electric vehicles.

Funder

GVA, Generalitat Valenciana

Programa de Apoyo para la Investigación y Desarrollo

Tecnologico de Monterrey

Publisher

MDPI AG

Reference27 articles.

1. International Energy Agency (2024, February 05). Electric Car Sales Break New Records with Momentum Expected to Continue through 2023. Available online: https://www.iea.org/reports/global-ev-outlook-2023/executive-summary.

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3. The immersion cooling technology: Current and future development in energy saving;Pambudi;Alex. Eng. J.,2022

4. Thermal management of Li-ion batteries with single-phase liquid immersion cooling;Sundin;IEEE Open J. Veh. Technol.,2020

5. Shell (2024, February 06). Electric Vehicle Fluids. Available online: https://www.shell.com/content/dam/shell/assets/en/business-functions/shell-lubricants/documents/shell-white-paper.pdf.

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