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The temperature of batteries in electric vehicles increases with time due to internal chemical reactions. This temperature rise is undesirable because it promotes corrosion and affects the battery life and thus a coolant can be used to prevent the temperature rise. The use of lightweight material and thermal management properties have a huge impact when designing a battery, especially, when using Aluminium foams it gives an exceptional advantage ranging from lightness, ductility to excellent absorption and conductivity making it a great deal for the future-oriented development of electric vehicles and market acceptance. The current research work tries to prove that Al foam can be used as a coolant in batteries of electric vehicles because of its porosity and density. The battery and Al foam are modelled in SOLIDWORKS and simulations are conducted in CFD and transient thermal to observe the heat transfer, flow characteristics and cooling effect on foam surface. The pores in Al foam are placed in three different patterns and two sizes (3mm and 5 mm) while modelling and hence six distinct models of Al foam are taken into study. The results from the simulations are compared and the Al foam that reduces maximum temperature at the outlet is chosen as the best coolant.

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