14 (2022) 100153

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International Journal of Thermofluids

journal homepage: www.sciencedirect.com/journal/international-journal-of-thermofluids

A critical review of the straight and wavy microchannel heat sink and the
application in lithium-ion battery thermal management
M. Hajialibabaei *, M.Z. Saghir
Dept of Mechanical and Industrial Eng, Ryerson University, Toronto, Canada

A R T I C L E I N F O A B S T R A C T

Keywords: As demand for high-performance heat transfer increases, interest in microchannel heat sinks as a viable solution
Microchannel heat sink for heat flux removal in thermal devices has grown significantly. Microchannel heat sinks with straight and wavy
Wavy microchannel designs are the two main varieties that have been the focus of extensive research in this field. The current paper
Nanofluids
provides beneficial information regarding the different designs and methods for heat enhancement and overall
Lithium-ion battery
thermal performance in straight and wavy microchannel heat sinks. Besides using nanofluids, modified designs
improve heat transfer performance due to incorporating secondary flow. Moreover, utilizing microchannels as
indirect cooling methods in lithium-ion battery thermal management is discussed in this review. This study
discusses current issues and future research directions.

1. Introduction
The increased demand for energy in the modern environment
necessitated the development of thermal devices with high-performance
heat transfer. Due to the high efficiency of heat transfer, a microchannel
heat sink (MCHS) has become increasingly popular in various industries.
Extensive studies were conducted by utilizing active and passive
methods to improve the performance of MCHS. The former requires
additional energy, whereas the latter is more efficient and does not
require extra energy [1]. The critical feature of micro-channel heat sinks
is the ability to integrate effective heat transfer performance, including a
higher surface area to volume ratio, a significant convective heat
transfer coefficient, low mass and volume, and a small coolant inventory
[2].
Tuckerman and Pease [3] pioneered high aspect ratio channels to
provide high-performance forced liquid cooling in electrical devices.
This research paved the way for further research on microchannel heat
sinks. After that, enormous researchers focused on improving thermal
performance in the microchannel heat sink. Both laminar and turbulent
flow regimes were investigated for deep channel systems [4]. The pri­
mary objective was to determine the best way to optimize average
temperature, pressure drop, heat transfer coefficient, Nusselt number,
flow, and substrate temperature uniformity. Designed characteristics,
including cross-sectional shape, pattern, header shape, and input/output
ports, were among the most effective parameters in investigations [5, 6,
7].
Most investigations focused on improving heat transfer at the
expense of increased pressure drop. This issue steered research into the
study of minimizing pressure drop while also enhancing thermal per­
formance [8,9]. The first category consists of a straight microchannel
heat sink. The common problems related to developing flow led to
research on thermal boundary layer re-development and secondary flow
generation [10]. Moreover, analyses addressed nonuniform temperature
distribution in a straight microchannel heat sink. Utilizing various
configurations and designs ensures tackling this issue through illustra­
tion, oblique fin, double-layer microchannel, and different pin-fin
[11–13]. One of the passive ways for researchers was a wavy channel,
an experimental study being presented by Sparrow and Comb is deemed
as an initial study on using corrugated walls [14]. Wavy channels are
associated with the increasing interfacial contact area, uniform wall
temperature condition, and improving the convection heat transfer co­
efficient [15,16].
The prominent importance relates to the application of mini chan­
nels in electronic devices [17] and lithium-battery thermal management
[18]. Since the performance of lithium-ion batteries in electric vehicles
is contingent on temperature, particularly during quick discharge and
charging, cooling techniques in these areas play a crucial role in the
battery’s efficiency and durability. Moreover, mini channel and micro­
channel heat sinks are deemed the most practical choice due to their
favorable properties when removing heat by convection from the

* Corresponding author.
E-mail address: mhajialibabaei@ryerson.ca (M. Hajialibabaei).

https://doi.org/10.1016/j.ijft.2022.100153

Available online 27 April 2022

2666-2027/© 2022 The Authors. Published by Elsevier Ltd. This is an open access article under the CC BY-NC-ND license (http://creativecommons.org/licenses/by-
nc-nd/4.0/).
M. Hajialibabaei and M.Z. Saghir
surface of a heat-generating device [19]. Commonly, thermal manage­
ment technology uses liquid cooling as a preferred method of cooling
[20].
The present paper aims to review straight and wavy microchannel
heat sink. The first section consists of effective parameters and different
designs in a straight microchannel, and the second section of this work
focus on wavy microchannel and modified designs. Moreover, using
nanofluids as cooling fluid is discussed for both types of microchannels.
The last section provides studies about the application of microchannel
cold plates for indirect cooling methods of lithium-ion batteries thermal
management. This paper includes comprehensive and recent informa­
tion for both straight and wavy microchannel heat sinks and classified
them as different designs and using nanofluid, in conjunction with their
application in the lithium-ion batteries industry. To our knowledge, this
classification is presented together for the first time.
2. Straight microchannel
As one pioneer works, Wang and Peterson [21,22] carried out an
experimental study to discover the fundamental physical nature of the
fluid in a microchannel. According to this study, a laminar flow transi­
tion occurred between Reynolds numbers 200 and 700, and this crucial
Reynolds number dropped as hydrodynamic diameters decreased.
Additionally, a correlation for the friction factor was presented. The
influence of geometrical channel characteristics on flow revealed that
the hydraulic diameter and aspect ratio plays a vital role in the liquid
flow and the flow friction performance. Furthermore, they developed a
relation between the Nusselt number and the Reynolds number to pre­
dict heat transfer in both laminar and turbulent flow. Maximum heat
transfer was observed in laminar flow with an aspect ratio of 0.75. To
better understand the effect of microchannel geometry configuration,
heat transfer and flow friction coefficients were determined in an
experimental study by Peng and Peterson [23]. They found a relation
between the laminar flow heat transfer aspect ratio and hydraulic di­
ameters. Moreover, a new dimensionless variable was defined to
describe turbulent flow heat transfer, which helps explain the effect of
the aspect ratio equal to the minimum (H/W) to maximum (H/W) which
was the ratio of height to width. Empirical correlations were used to
determine both heat transfer and pressure drop.
For a binary mixture (water and methanol) through microchannels,
Peng and Peterson [24] investigated the single-phase heat transfer in
experimental research. They found laminar heat transfer ended at a
lower Reynolds number bound of 70–400 depending on the flow con­
ditions, and fully turbulent convective heat transfer was accomplished at
a Reynolds number of 200–700 depending on the hydraulic diameter of
the microchannel. The impact of the aspect ratio on heat transfer and
fluid flow is essential, and its effect on convective heat transfer varies
depending on the mole fraction of the mixture. Moreover, as the mass
flow rate through microchannels increased, the region in which heat
transfer was enhanced grew larger. To explain some phenomena in a
microchannel, Mala et al. [25] introduced an interfacial electric double
layer (EDL) through a microchannel between two parallel plates. The
arrangement of the electrostatic charge on the solid surface and the
balancing charges in the liquid was called the EDL. The EDL was the
arrangement of the electrostatic charges on the solid surface and the
balancing charges in the liquid. The EDL resulted in a lower flow ve­
locity than conventional theory, altering the temperature distribution
and lowering the Reynolds number.
Harms et al. [4] examined both laminar and turbulent flow regimes
experimentally for single and multiple deep channel systems. When
laminar flow developed, the overall performance of this system
increased and that laminar flow performed better than turbulent flow.
More investigations on turbulent single-phase convection in circular
microchannels were studied by Adams et al. [26]. Nusselt numbers for
water flowing through circular channels of dimensions 0.76 and 1.09
mm were experimentally determined and indicated that the Nusselt
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International Journal of Thermofluids 14 (2022) 100153
number in microchannels was greater than the traditional channel. A
correlation was presented for the Nusselt number in turbulent and
single-phase flow.
Xu et al. [27] investigated flow in microchannels using two channels
made of aluminum plates and silicon wafers for modeling microchannel
heat sink. They discovered that Navier-Stokes equations were ineffective
at predicting flow characteristics in channels greater than 30 µm in
hydraulic diameter. The microchannel was manufactured using a silicon
wafer with an etched channel and Pyrex glass using anodic bonding.
However, in a numerical and experimental study, Qu and Mudawar [2]
investigated heat transfer and pressure drop in a microchannel heat sink.
The authors found the traditional Navier–Stokes and energy equations
can model micro-channel heat sinks appropriately. Lee et al. [28] con­
ducted an experimental investigation of the validity of classical corre­
lations. Their experiment consisted of 10 parallel copper microchannels
with hydraulic diameters ranging from 318 to 903 μm. The experimental
approach had good agreement with numerical prediction based on the
classical continuum approach and Reynolds numbers varied from 300 to
3500. Consequently, the main parameters of microchannel heat sink
were investigated by many researchers and there has been compre­
hensive information about the fluid flow and heat transfer for both
laminar and turbulent flow.
2.1. Effective parameters in a straight microchannel
According to studies, a range of factors can affect fluid flow and heat
transfer in microchannels utilized in optimized designs. Ryu et al. [29]
optimized the design parameters of the microchannel in 3D analysis to
decrease heat resistance. Given that the influence of entry was investi­
gated, the channel width appeared to be the most important factor in
defining the performance of a microchannel heat sink. The effect of
changing channel height and widths in a 3D microchannel heat sink was
investigated by Sen Kou et al. [30] in a numerical study. They achieved
the lowest thermal resistance and the optimal channel width and height
using simulated annealing methods. In a numerical study, the effect of
various inlet and outlet arrangements on fluid flow and heat transfer in
microchannel heat sink was investigated by Chein and Chen [31]. The
heat sinks with coolant supply and collection vertically via inlet and
outlet on the heat sink cover plate had superior velocity and temperature
uniformity. It is suggested that enhanced heat sink performance can be
attained by delivering and collecting coolant vertically. A numerical
simulation and parameter sensitivity analysis were provided to evaluate
the effective parameters in a straight microchannel [32]. In this way,
flow and heat transfer characteristics were analyzed using a combina­
tion of CFD simulation and the machine learning method. When the
Reynolds number was low, the number of channels and Reynolds
number were significant factors in heat transfer. However, as the Rey­
nolds number increased, the number of channels became an effective
parameter for heat transfer and flow. Additionally, the aspect ratio and
cross-section area affected pumping power by low Reynolds numbers.
By considering effective parameters, many studies concentrated on
optimizing microchannel heat sinks. Heat transfer performance of
silicon-based parallel microchannel was investigated by Li and Peterson
[33] in a numerical study. They demonstrated the micro channel’s
optimal geometric characteristics and indicated that the overall cooling
capacity increased by more than 20%. Thermal resistance was
0.068 ◦ C/W, when a pumping power of 2 W was used. The geometry of
the microchannel heat sink can be optimized using finite volume tech­
niques to reduce the peak temperature from wall to fluids while the
pressure difference is fixed. The effect of total solid volume fraction and
pressure drop on the aspect ratio, the hydraulic diameter of the channel,
and the peak temperature was investigated by Bello-Ochende et al. [34].
The numerical findings indicated that degrees of freedom significantly
affect the maximum thermal conductivity and peak temperature.
Naquiuddin et al. [35] used the Taguchi-Gray optimization tech­
nique to optimize a novel segmented micro-channel heat sink. Using 15
M. Hajialibabaei and M.Z. Saghir
gs− 1 of water, the optimized micro-channel heat sink can cool the chip
with a heat flux of 800 W to 56.6 ◦ C and pumping power of 0.13 W.
Yildizelip et al. [36] optimized conjugated heat transfer in the micro­
channel heat sink using a multi-objective genetic algorithm. The opti­
mization approach results in the optimal trade-off between convective
heat transfer and pumping power, which are mutually incompatible.
This technique was determined to be an advantageous method for
optimizing the hydrodynamic and thermal parameters of the MCHS. A
high aspect microchannel heat sinks optimized power consumption and
thermal performance for Reynolds numbers ranging from 13 to 360 with
the ANSYS-Fluent flow solver connecting with the MATLAB optimiza­
tion method [37]. Results showed increasing aspect ratio up to a
particular point resulting in a reduction in pressure drop and increased
thermal performance. In comparison to other studies, optimization was
based on minimum pumping power. Considering these findings, both
heat transfer and pumping power were optimized in terms of geometric
parameters utilizing a range of variables and objective functions.
2.2. Different designs of straight microchannel
Numerous active and passive strategies can be used to improve the
thermal performance of microchannel heat sinks to develop a design in
which the benefit of increased heat transfer balances the disadvantage of
increased pressure drop. For instance, single-phase heat transfer
enhancement techniques have been identified as possibilities for
microchannel enhancement [38]. In terms of cross-section, in compu­
tational analysis, Wang et al. [39] explored the influence of various
shapes, including rectangular, trapezoidal, and triangular-shaped, in a
straight microchannel heat sink and determined the impact of channel
numbers. Thermal resistance was lowest in the rectangle, whereas it was
highest in the triangular microchannel. Moreover, increasing the num­
ber of channels reduces heat resistance, however, at the penalty of a
significant pressure drop. The rectangular microchannel with an aspect
ratio between 8.904 and 11.442 demonstrated the greatest performance.
In a numerical and experimental study, the heat transfer perfor­
mance of a triangular silicon micro-channel was studied by Tiselj et al.
[40]. Dehghan et al. [41] investigated a converging flow passage in
microchannel heat sinks for three distinct maximum pressures (1500 Pa,
2000 Pa, and 3000 Pa) and four different tapering designs within the
range of 75–350 Reynolds numbers. They obtained Nusselt number
increased as the entrance impact of the flow diminished. The optimum
heat transfer performance was achieved with a width-tapered ratio of
0.5 and a maximum pressure limitation of 3000 Pa. Compared to a
straight channel, the pumping force is reduced by a ratio of four.
Secondary flow in a microchannel heat sink can drastically improve
thermal performance with additional pressure drop. Raja Kuppusamy
et al. [42] developed a microchannel heat sink with the secondary flow
to enhance heat transfer and mitigate pressure drop using a slanted
passage. MCHS’s overall performance increased by 146% to basic
MCHS, while thermal resistance dropped by 76.8%. Additionally, pres­
sure drop decreased by 6%. Tikadar et al. [43] developed a new
water-cooled inter-connected counter flow mini-channel sink (ICMCHS)
to improve thermal-hydraulic performance by disrupting the hydraulic
and thermal boundary layers. They studied nine examples with different
interior positions and widths utilizing two interconnectors that divided
the flow domain into three zones. Due to pressure differences, this
design resulted in secondary flow. Results showed that independent of
the interconnector’s position and width, the secondary flow decreased
gradually as the Reynolds number increased. Zhang et al. [44] optimized
heat transfer and pressure drop by employing relative parameters and
design methods for the finned microchannel with a secondary channel in
an experimental and numerical investigation. By altering the arrange­
ment (the aligned, staggered), angle, lateral and vertical spacing of fins,
the improved design resulted in a 6.75% and 13.33% reduction in
average temperature and pressure drop, respectively, compared to the
straight microchannel. The performance evaluation was 1.285.
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International Journal of Thermofluids 14 (2022) 100153
Moreover, an inverse proportional relationship between the angle of the
fin and the pressure drop was obtained, which became more noticeable
as the mass flow rate increased. In comparison to other studies, they
aimed to find the impact of fin pitch parameters in various directions.
Instead of continuous fins, sectional oblique fins were employed to
manage the flow in microchannel heat sinks by Lee et al. [45]. This
design re-initialized the thermal boundary layer at the leading edge of
each oblique fin, greatly diminishing the boundary layer’s thickness. As
a result of the regeneration of entrance effects, the flow was constantly
developing, leading to higher heat transfer. Using an oblique fin with a
higher density was more effective when heat flux increased. Addition­
ally, adjusting the oblique fin pitch could alleviate hot areas. Compared
to the usual approach, the variable pitch oblique finned microchannel
demonstrated a greater than 100% increase in the local heat transfer
coefficient in the high heat flux area. As a result, both the maximum
temperature and the temperature gradient of the system were decreased
by 12.4 ◦ C.
Compared to traditional enhancement approaches, this design has a
low or non-existent pressure drop penalty. Moreover, smaller oblique
channels created secondary flows that assisted in fluid mixing and
improve heat transfer [46]. Heat transfer performance and uniformity
were significantly enhanced. The average Nusselt number increased by
103% when copper microchannel heat sinks were used with water as the
working fluid. The pressure drop penalty was negligible compared to the
heat transfer improvements obtained. In a succeeding study, Lee et al.
[10] conducted a parametric study to determine the performance of a
microchannel heat sink with an oblique angle and fin pitch. Smaller
angles and pitches were favorable for redeveloping thermal boundary
layers and the formation of secondary flows, and the optimal angle was
determined to be 27 ◦ C. In terms of secondary flow, using slanted pas­
sage, interconnectors, fins, and oblique fins can enhance the thermal
performance; however, the pressure drop of oblique fin is lower than
conventional heat transfer enhancement methods. A summary of
different designs in straight microchannel is provided in Table 1.
To assist in maintaining the re-developing flow, various shapes of
pin-fins were implemented to improve convective heat transfer. Polat
et al. [47] researched to determine the optimal configuration and ge­
ometry of the pin-fin microchannel heat sink, including diamond,
square, and circular-shaped pin-fins. Fig.1 showed the schematic of
three different shapes of pin-fins. Optimal designs were found
throughout a wide range of porosity values, most noticeably around the
upper limit of the pin-fin Reynolds number, with average Nusselt
numbers ranging from 3 to 12 and corresponding pressure drop ratios
ranging from 1 to 12. The best thermal performance was achieved with a
diamond-shaped pin-fin because has high heat transfer enhancement
with rising pressure ratio. Bhandari and Prajapati [48] employed a
square pin profile in an open microchannel heat sink to study overall
thermal performance for Reynolds numbers ranging from 100 to 800.
They optimized fin height and discovered that boosting the fin height in
a heat sink enhanced the heat transfer rate, but only up to 1.5 mm of fin
height.
Ismayilov et al. [49] provided a systematic approach for parame­
trizing hydrofoil shape pin fins for micro heat sinks and determining the
impacts of geometrical factors. In this work, a genetic algorithm with a
computer-based algorithm was employed in conjunction with CFD
simulations. The rise in average heat transfer coefficient outweighed the
increase in pressure drop at higher Reynolds numbers. Yan et al. [50]
developed a micro heat sink with four gradient distribution pin fin ar­
rays in narrow slots to reduce pressure drop. Pressure drop reduction
was obtained 28.7% and 33.4% compared to the conventional gradient
distribution. Although the suggested enhanced gradient distribution pin
fin had a more significant pressure drop, it increased the heat transfer
effect considerably. Utilizing different blind holes and pillars was
introduced by Rajalingam et al. [51] to enhance heat transfer perfor­
mance in the microchannel heat sink. Different shapes of pillars and
holes in the microchannel heat sink are depicted in Fig.2. The heat
M. Hajialibabaei and M.Z. Saghir International Journal of Thermofluids 14 (2022) 100153

Table 1 Table 1 (continued )

Summary of different designs in straight microchannel heat sink. Purpose Type of design Source Remarks/Outcomes
Purpose Type of design Source Remarks/Outcomes
Open transfer and pressure
Utilizing Slanted passage Raja 146% increase in microchannel drop
secondary Kuppusamy overall performance heat sinks The highest heat
flow, et al. [42] 76.8% drop in thermal transfer coefficient
Re- resistance was found with a fin
developing 6% decrease in height of 0.8 mm
flow pressure drop Using fin Kadam et al. 15% increases in heat
Sectional oblique Lee et al. [45] Significant (extended surface) [69]. transfer performance
fins [46]. improvement in Reducing 3.7 ◦ C in
temperature maximum wall
uniformity temperature&
More than 100% 18% rise in pressure
increase in the local drop
heat transfer
coefficient
Pin fins: Polat et al. Diamond-shaped pin- transfer coefficient of the MCHS with the proposed design was deter­
(diamond, square, [47] fins demonstrated the mined to be 1.61 to 1.7 times that of a plain microchannel under the
and circular- highest thermal
same circumstances. Additionally, thermo-hydraulic performance
shaped) performance and the
lowest hydrodynamic increased from 12.4% to 16.5%. The MCHS with elliptical pillars pro­
performance. vides the best thermo-hydraulic performance. Thus, different shapes and
Blind holes and Rajalingam Increase in heat geometries were optimized and compared to find the minimum pressure
pillars et al. [51] transfer coefficient, drop with acceptable heat transfer enhancement, while assessment of
1.61 to 1.7 times
2.4 to 16.5% rise in
different configurations of a combination of high-performance shapes
thermo-hydraulic can be investigated in the next studies.
performance Utilizing offset ribs on the sidewall of a microchannel was explored
The best thermo- by Chai et al. [52] numerically. For Reynolds numbers ranging from 190
hydraulic
to 838, rectangular, backward triangular, isosceles triangular, forward
performance was
obtained for elliptical triangular, and semicircular ribs were constructed in this investigation.
pillars The Nusselt number and friction factor of the microchannel heat sink
Offset ribs Chai et al. [52] Reynolds numbers with offset ribs were 1.42–1.95 and 1.93–4.57 times more than those of
ranging from 190 to the smooth microchannel heat sink, respectively, yielding performance
838
1.42–1.95 times
evaluation criteria of 1.02–1.48 depending on the offset rib arrange­
higher Nusselt number ment. Additionally, as Reynolds numbers increased, the microchannel
1.93–4.57 times heat sink with offset ribs gradually lost its effectiveness as a heat transfer
increase in friction enhancement method due to significant pressure drops. Xiao et al. [53]
factor
used the inclined parallelepiped rib to evaluate the pattern of multiple
Vertical porous Shamsoddini 2.16, 2.1, and 1.3
ribs Lori and Vafai times increase in Nu longitudinal swirls flows in mini-channel heat sinks. The substrate
[54] number rather than dimension of the mini-channel heat sink was 30 mm × 30 mm, and the
the solid case Reynolds number ranged from 100 to 1100. Within a temperature dif­
2.505, 3.62, and 4.01 ferential of 60 K between the substrate and the fluid, the maximum
times increase in Nu
number compared to
average heat flow rate was 3.2 × 106 W/m2.
the no-ribs channel Shamsoddini Lori and Vafai [54] compared the performance of solid
Significantly fewer and porous ribs in micro-channel heat sinks. Periodic vertical rectan­
pressure drops than a gular, elliptical, triangular, backward triangular, forward triangular
solid case
porous ribs could enhance the average Nusselt number in straight
Double-layer Double-layer Leng et al. [60] Using a three-
microchannel microchannel dimensional model microchannel maximum of 2.16 and 4.01 times, compared to solid ribs
heat with truncated top and a simplified and no-rib microchannel. Porous ribs presented a lower pressure drop in
channels conjugate-gradient comparison to solid ribs. Moreover, the width, depth, incline angle, and
method for distance between adjacent offset ribs of distinct offset ribs were exam­
optimization
The reduced influence
ined using fuzzy gray relation analysis (FGRA) and an orthogonal
of the upper layer’s experiment design [55]. For Reynolds number equal to 1000, the opti­
heating on the bottom mum design was achieved for novel S-shaped staggered triangular offset
layer ribs with 45 inclined angles with 1.36 performance evaluation criteria.
Staggered double Shen et al. [61] A uniform
The principle of a double-layer microchannel heat sink was intro­
channel temperature
difference by duced by Vafai and Zhu [56]. Microchannels with two layers have
increasing the number reduced thermal resistance, requiring less pumping power [57]. Lin
of multiple staggered et al. demonstrated the optimal shape for a double-layer microchannel
flows heat sink in a water-cooled system, providing a valuable reference for
Superior thermal
performance for a
the practical design of a double-layer MCHS [58]. Xie et al. [59]
single alternation discovered that counter-flow double-layer microchannels perform better
structure in larger flow rates and uniform temperature rise. However, parallel
Modified cross- Debbarma et al. Lower pressure drops flow demonstrated superior performance at slightly higher flow rates.
section [64] equal to 52.47 kPa
Temperature uniformity was greatly improved in a conventional double
Varied the height Prajapati [66] Increasing fin height
of fins leads to higher heat layered microchannel heat sink. However, the temperature of the top
coolant is always greater than the temperature of the bottom coolant at
the inlet region of bottom channels, resulting in an inevitable heating

4
M. Hajialibabaei and M.Z. Saghir
Fig. 1. the schematic of three different shapes of pin-fins in microchannel heat sink [47].
Fig.2. Different shapes of pillars and holes in microchannel heat sink [51].
impact of the top coolant on the bottom coolant. Leng et al. [60] opti­
mized a novel double-layer microchannel with truncated top channels.
The optimizations were carried out at various fixed pumping powers and
constant volumetric flow rates of coolant.
The staggered flow alternation structure, which impacts the flow
swapping between the two channels in the core section of double-layer
microchannel heat, can improve overall thermal performance. Conse­
quently, Shen et al. [61] developed a novel structure with a variety of
staggered flow alternation patterns for parallel and counter streams. An
innovative mixed-flow X structure in a double-layer microchannel heat
sink improved temperature uniformity while maintaining an excellent
rising pumping power [62]. Debbarma et al. [63] modified the geometry
of the double-layer microchannel heat sink and investigated the influ­
ence of protrusions on the sidewall with two different dimensions.
Protrusions on the channel sidewall improved performance in the case of
a double-layer microchannel heat sink with higher Nusselt number and
heat transfer coefficient. In another study, Debbarma et al. [64] inves­
tigated a modified cross-section for a double-layered microchannel in
which the top layer of channels was divergent. There was a considerable
improvement with higher Reynolds numbers. This novel design resulted
in a decreasing pressure drop at the top layer’s upper section, 52.47 kPa
at the maximum Reynolds number.
Due to the limitation of cooling performance in the upper layer of the
double-layer straight microchannel, Shen et al. [65] offered a new
design with two different deflectors for improved flow mixing. Fig. 3
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International Journal of Thermofluids 14 (2022) 100153
shows the schematic of the double-layer microchannel heat sink with
deflectors. This design showed an acceptable performance factor despite
the high-pressure drop and outweighed the straight double-layer
microchannel. The peak temperature was 7k lower than that of a
straight double-layer microchannel. All modified designs attempted to
overcome the disadvantages of conventional double-layer micro­
channels in terms of top layer temperature, while thermal performance
is entirely dependent on the Reynolds number range; for instance,
changing the cross section was only applicable at higher Reynolds
numbers.
By using open microchannel heat sinks, open space above the fin top
can tackle the problem of uniform coolant distribution necessarily at the
channel entrance. Moreover, this design is associated with a reduction in
material usage. Prajapati [66] varied the height of fins in the rectangular
parallel microchannel to find maximum heat transfer performance. Heat
transfer improved as fin height increased while leading to a rise in
pressure drop. When the fin height is 0.8 mm, maximum heat transfer
was achievable due to the open space in this design, which corresponded
to the convective heat surface and flow behavior. Due to the merit of the
open microchannel in boiling, Yin et al. [67] studied design parameters
and operating conditions in this type of microchannel experimentally.
The thermal performance of flow boiling of R134a in an open micro­
channel heat sink was investigated by do Nascimento et al. [68]. A
comparison between Palin and finned (extended surface) open micro­
channel heat sink was presented by Kadam et al. [69]. Findings showed
M. Hajialibabaei and M.Z. Saghir
Fig.3. The schematic of a double-layer microchannel heat sink with deflectors [65].
that heat transfer performance improved by 15%, whereas the expanded
surface open MCHS experienced a pressure drop penalty of approxi­
mately 18% owing to the extended surfaces. Thermal performance, in
general, revealed that open channels might be a reasonable alternative.
The development of a two-phase flow microchannel heat sink was
presented by Lee et al. [70]. They investigated density wave oscillation
and parallel channel instability in a copper microchannel with 38
straight rectangular channels. Alugoju et al. [71] presented a numerical
simulation to investigate conjugate flow boiling in a diverging micro­
channel to analyze bubble patterns. The heat transfer coefficient
decreased with increasing diameter. When comparing straight and
divergent channels, the latter took advantage of instability mitigated
flow boiling. To predict the flow regime and its transition along with the
microchannel heat sink, Yeo et al. [72] presented a two-dimensional
computational model for flow boiling of R134a.
2.3. Nanofluids in straight microchannel
Nanofluids can provide significant benefits as coolants in thermal
management systems. Due to improved flow mixing and increased heat
transfer rate, nanofluids became increasingly attractive for development
in microchannel heat sinks [73]. Aglawe et al. [74] proposed a mathe­
matical model for heat transfer coefficient and used dimensional analysis
by employing the Buckingham Pi theorem. Based on the results, the heat
transfer coefficient of the microchannel heat sinks with nanofluids as
coolants can be predictable. Wang et al. [75] utilized inverse geometric
optimization to determine the temperature-dependent thermophysical
characteristics of, Al2O3 Nanofluid-cooled microchannel. They used the
optimization tool being a three-dimensional fluid-solid conjugated MCHS
model integrating the simplified-conjugate-gradient-method. Pumping
power influenced the optimum MCHS design: in the low-power pumping
regime, increasing pumping power improved cooling performance.
Numerous parameters such as channel number, channel aspect ratio, and
width ratio of channel to pitch were optimized concurrently under the
constraint of a fixed inlet volume flow rate, fixed pumping power, and
fixed pressure drop.
To further experimental development in a microchannel heat sink
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International Journal of Thermofluids 14 (2022) 100153
with nanofluids, Jung and Park [76] employed particle image veloc­
imetry (PIV) and laser-induced fluorescence measurement techniques to
study heat transfer in a microchannel with Al2O3 Nanofluids. This article
delved into the velocity and temperature distributions of nanofluid flows
in MCHS. By evaluating entropy generation, thermal entropy was 6.3%
lower than that of water. The performance of a microchannel heat sink
subjected to non-uniform heat flux was investigated by using Al2O3
Nanofluids as the cooling fluid. The average surface temperature drop­
ped with increasing volume concentration from 0.1% to 0.25% for both
uniform and non-uniform heat flow [77]. Ting et al. [78] investigated
the effect of streamwise conduction under exponential wall heat flux as
boundary conditions on the heat transfer of nanofluids in the micro­
channel heat sink. Streamwise conduction had a negligible effect for
nanofluids with a high fraction and a low Peclet number. The func­
tionalized Graphene Nanoplatelets suspended in distilled water were
utilized in a microchannel heat sink by Balaji et al. [79] to enhance
thermal conductivity. Based on experiments, when compared to water,
the heat sink reduced the temperature by 10 ◦ C and increased the
convective heat transfer coefficient and Nusselt number by 71% and
60%, respectively, with a slight increase in pressure drop of around 12%.
To further elucidate the previous investigation on the use of nanofluid in
microchannel heat sinks, Alkasmoul et al. [80] investigated the thermal
and hydraulic properties of various nanofluids and identified the
optimal nanoparticle concentration. Due to the effect of using nanofluids
in rising viscosity, it was crucial to consider hydraulic performance in
the thermal performance of nanofluids.
Using nanofluids in conjunction with modifying the geometrical
characteristics of the microchannel heat sink has been developed to
improve thermal performance criteria. Single-layer microchannel heat
sinks experienced problems with temperature uniformity across the
channel length. Ahmed et al. [81] conducted an experimental investi­
gation on a double-layer microchannel with rectangular and triangular
rounded corners. They experimented with two distinct nanofluids, Al2O3
and SiO2-Al2O3 demonstrated the best performance, and the triangular
shape provided a more uniform temperature distribution. Moreover,
Hung and Yan [82] proposed a double-layer microchannel with Al2O3 as
nanofluid which resulted in 26% increase in thermal performance.
M. Hajialibabaei and M.Z. Saghir International Journal of Thermofluids 14 (2022) 100153

Akbari et al. [83] utilized Al2O3 nanofluids as a coolant in a straight Table 2

microchannel with varying rib height as the Reynolds number increased Summary of using nanofluids in straight microchannel heat sink.
from 10 to 100. The friction coefficient and average Nusselt number Source Types of design Working fluid Remarks
increased as the height of ribs and volume fraction of nanoparticles were
Hung and Yan Double-layer Al2O3 26% average
elevated. Tiwary et al. [84] conducted an experimental and numerical [82] microchannel improvement in thermal
investigation to determine the combined impact of oblique fins and performance for
Al2O3 Nanofluids in a microchannel heat sink. A 2% volumetric con­ nanofluid with 1%
centration of nanofluids boosted the heat transfer coefficient by 55%. A Akbari et al. Different Al2O3 Reynolds numbers
[83] heights of ribs ranging from 10 to 100
straight microchannel heat sink with Al2O3 as coolant was examined to 0.04 vol fractions for
using a pin fin and vortex generator combination to increase flow nano particles
disturbance and mixing flow [85]. The schematic diagram of pin fins and Increasing Nu number
vortex generators is demonstrated in Fig.4. Between three distinct with rising the heights of
ribs and volume fraction.
pin-fin forms, oval, diamond, and round, the best hydraulic and thermal
Tiwary et al. Oblique fins Al2O3 The enhancement of
performance was achieved for the oval design. The maximum heat [84] about 55% improvement
transfer performance was achieved with a 4% volume nanofluid con­ of the heat transfer
taining Al2O3 nanoparticles with a diameter of 20 µm. coefficient for nanofluid
Regarding the utilization of nonfluids and porous media, Nojoomi­ with 2% volumetric
concentration and Re
zadeh et al. [86] conducted numerical research on the forced convection number 300
heat transfer of a nanofluid consisting of water and Fe3O4 nanoparticles Reynolds numbers range
in a two-dimensional microchannel filled with porous material in half. between 100 and 300
When the Darcy number decreased, the local Nusselt number increased Nojoomizadeh Using porous Fe3O4 Reynolds numbers
et al. [86] material ranging from 25 to 100
in the non-porous zone while decreasing in the porous zone. Addition­
Darcy number was equal
ally, the local Nusselt number rose when the Reynolds number increased to 0.1 and 0.01
due to the growing velocity of nanofluids. Utilizing different concen­ Nu number raised in non-
trations of aluminum oxide nanofluid and porous media in a straight porous portions and
microchannel heat sink was implemented by Plant and Saghir [87] in an declined in porous
portions when Darcy
experimental and numerical study. They evaluated different sections
number decreased
using two and three channels while the heat flow varied between 3.8328 V. Murali Rectangular Cu Al2O3 Hybrid nanofluids in
and 10.3737 W/cm− 2. Results showed a maximum 24.5% thermal Krishna et al. microchannel /water hybrid different mixing ratios of
enhancement for nanofluids with 1% concentration compared to 2% [92] nanofluid 25–75%, 50–50%, and
75–25%&
nanofluids concentration [87]. Wang et al. [88] demonstrated a heat
13.2% and 23.07%
sink composed of solid and metal foam. They developed two distinct increase in Nu number
models by altering the position of metallic porous materials and incor­ comparison to mono
porating hybrid nanofluids. These two arrangements were identical in nanofluids for 2.5%
volume but had substantially different contact surfaces with the solid volume fraction
Hesani et al. Grooved helical Biological Improvement of 21% in
fins. The metallic foam significantly improved heat transfer in the heat
[94] microchannel water-silver heat transfer coefficient
sink. The temperature with porous material was 8–9◦ lower than the nanofluid by increasing the
temperature of heat sink without porous. Literature on nanofluids in concentration of
straight microchannel heat sinks is given in Table 2. There are a limited nanofluids from 0% to
1%
number of research investigating the use of novel nanofluids in micro­
channels equipped with heat transfer enhancement modifications. More
researchers concentrated on using Al2O3, thus the performance of other

Fig.4. The schematic diagram of pin fins and vortex generators in microchannel heat sink [85].

7
M. Hajialibabaei and M.Z. Saghir
nanofluids and working on their stability in microchannel heat sinks can
be recommended for future studies.
The application of two distinct hybrid nanofluids, Al2O3-SiO2/water
and Al2O3–Cu/water nanofluid was studied in a double-layer micro­
channel heat sink under constant Reynolds number and constant flow
rate circumstances [89]. In comparison to pure water and Al2O3–Cu/­
water nanofluid, the Al2O3-SiO2/water nanofluid had higher Nusselt
numbers. Ionic liquid-Al2O3 Hybrid nanofluid was employed by Hei­
darshenas et al. [90] to cool the cylindrical microchannel heat sink. The
results indicated that hybrid nanofluids were more stable over time than
alumina nanoparticles. Plant et al. utilized mono and hybrid nanofluids
in a straight microchannel hat sink. The maximum performance of the
three-channel heat sink was increased by an average of 37.3% when 0.5
wt% TiO2 - SiO2 double nanofluid was used instead of water [91]. In a
recent study, a Cu-Al2O3 /water hybrid nanofluid was employed in a
rectangular microchannel heat sink, and the results were compared to
mono nanofluids[92]. Hybrid nanofluid was followed by lower pumping
power and 430 Pa higher than pure water. However, rather than mono
nanofluids of Cu-water (H2O) and Al2O3 water, the Nusselt number
increased by 13.2% and 23.07%.
In a microchannel fitted with rectangular ribs and sinusoidal cav­
ities, a novel hybrid aqueous nanofluid containing reduced graphene
oxide was investigated by Jamshidmofid and Bahiraei [93]. For Rey­
nolds numbers between 100 and 500, nanofluid concentrations of
0.05%, 0.1%, and 0.2% reduced the creation of vortices but increased
thermal conductivity. Overall, the effects of increasing heat transfer
outweighed the associated pressure drop. Moreover, Hasani et al. [94]
used biological water-silver nanofluid in a grooved helical microchannel
heat sink. They simulated plain; parallel grooved, and staggered helical
microchannels. In Reynolds numbers ranging from 500 to 2000, the
microchannel with staggered grooves had the highest performance
evaluation criterion. Consequently, there have been few studies on uti­
lizing new types of hybrid nanofluids in heat transfer performance of
microchannel heat sink.
3. Wavy microchannel
The wavy microchannel heat sink has been deemed as one of the
several methods employed for increasing heat transfer efficiency. Burns
and Perkes [95] was one of the first to analyze viscous flow in wavy
channels. Heat transfer in two-dimensional wavy channels with the fully
developed laminar flow was numerically evaluated, and corresponding
pressure drop was found greater than straight channels [96]. The
naphthalene sublimation technique was employed in an experimental
investigation to determine the local and average heat transfer properties
and the flow was classified as laminar, transition, or turbulent with a low
Reynolds number [97]. Sparrow et al. [98,99] examined heat transfer
and flow in a corrugated-wall duct by investigating inlet condition, in­
terval spacing, and protruding edge. Saidi et al. [100] investigated
laminar flow in a sinusoidal cavity and discovered that vortexes formed
inside the hollow when flow velocity increased, affecting dynamic and
thermal parameters. Considering moderate Reynolds numbers of
20–300, two different wall shapes were investigated: sinusoidal and
arc-shaped walls [101]. Due to an unsteady vortex motion in furrows in
the wall, the wavy wall channel possesses high heat transfer enhance­
ment. Wang and Vanka [102] found that, despite a 2.5-fold increase in
heat transfer, friction factors for the wavy channel were nearly double
those for the parallel-plate channel in the transitional flow regime. Russ
and Beer [103] explored the impact of altering wavelength and ampli­
tude on friction factors for Reynolds numbers ranging from laminar to
turbulent.
The hydrodynamic and thermal characteristics of a pipe with sinu­
soidal wavy sides were examined by Mahmud et al. [104] in numerical
research. The effect of surface waves on flow pattern, shear stress,
pressure drop, and heat transfer was explored in this study by using a
converging-diverging pipe. Interest in low Reynolds number flow has
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International Journal of Thermofluids 14 (2022) 100153
grown due to the increasing demand for compact heat exchangers [105].
The effect of aspect ratio was investigated numerically in a fully
developed region of a wavy channel. Both Nu number and friction factor
increased when the aspect ratio decreased. Ramgadia and Saha [106]
investigated a sinusoidal wavy channel by altering the length of the
periodic domain. Because the channel geometry formed by a single
sinewave was adequate for forecasting fluid flow and heat transfer, these
parameters were not reliant on the periodic domain length. The range of
Reynolds numbers was chosen to be between 25 and 1000 to observe the
impact of Reynolds numbers.
Sui et al. [107] discovered that secondary flow (dean vortices) was
created in the wavy microchannel and that the quantity and location of
these vortices could be varied along the flow direction. Due to chaotic
advection, this effect resulted in enhanced heat transfer performance.
Additionally, they investigated the relative wavy amplitude, defined as
A/L (wavy amplitude/wavelength). Increases in relative wave ampli­
tude along flow direction enhanced heat transfer performance and more
uniform temperature distribution across devices. Secondary flow (dean
vortices) could be generated for flow in a curved passage which
rendered stretching and folding of the flow. This impact increased the
rate of heat transfer. The traditional Navier–Stokes equation has been
the subject of considerable debate when it comes to evaluating fluid flow
and heat transfer in microchannels. Moreover, Sui et al. [108] evaluated
laminar and transitional flow in a wavy channel using a numerical study.
They discovered that wavy channels generate secondary flow that is
symmetric with chaotic advection. This effect contributes to the effi­
ciency of convective fluid mixing and heat transfer. Dean vortices
became more complex as the Reynolds number increased in transition
flow, and flow symmetry disappeared. A wavy wall channel improves
heat transfer because of the efficient mixing while reducing subsequent
pressure loss. In comparison, wavy wall microchannels possessed
recirculation zones and secondary flows, and the velocity vectors were
not parallel to the walls, which mean that these parameters were altered
by changes in the Reynolds number and geometrical characteristics
[109]. Additionally, the temperature distribution at the interface
boundary varied due to the geometrical characteristics.
3.1. Effective parameters in wavy microchannel
The geometrical complexity of these channels exerts a considerable
influence on the flow patterns. Different factors, including amplitude,
wavelength, phase angle, interval spacing, corrugation angles, sharp­
ness or roundness of successive peaks and valleys of the wall, can be
explored to identify the consequential impacts of a wavy channel on the
fluid flow [104]. The wavelength, wave amplitude, phase angle, and
wall-to-wall spacing were all altered by Rush et al. [110]. to evaluate
local heat transfer in laminar and transitional flow. Foo et al. [111]
examined the utilization of the wavy microchannel in macro geometry
and discovered that microchannels with larger amplitude and shorter
wavelengths performed better. Overall, 51% greater heat removal could
be accomplished at the same pumping power as compared to the con­
ventional annular channel.
A numerical study of fluid flow and heat transfer in sinusoidal and
arc-shaped configuration wavy channels was used to determine the ef­
fect of geometric factors on the steady laminar flow [112]. Increasing
two defined parameters, being length ratio (Wavelength/ Half of
amplitude) and height ratio (Minimum height/ Maximum height),
decreased the recirculation size and strength. Mohammed et al. [113]
investigated heat transfer and flow characteristics in a 3D wavy micro­
channel. They used finite-volume methods and found better heat
transfer performance for wavy channels compared to straight channels.
By increasing the amplitude of the wavy microchannel, both friction
factor and shear stress increased. Moreover, heat transfer enhancement
is much more than pressure drop demerits. In this study, wavy ampli­
tude varied from 125 to 500 μm, and Reynolds was 100–1000. An
optimal overall thermal performance can be achieved in dimensionless
M. Hajialibabaei and M.Z. Saghir
wavy amplitude equal to 0.0625 to 0.21875 in the wavy microchannel.
Lin et al. [114] investigated the design of a wavy microchannel to alter
wavelength and amplitude in the direction of flow. Lower thermal
resistance and a smaller temperature difference at the bottom of the wall
are induced by lowering wavelength or increasing amplitude. This
design was more efficient for heatsinks with small channel aspect ratios.
Considering that other parameters such as surface roughness, which
substantially influence the flow field and heat transfer performance,
were not considered in numerical simulation, Sui et al. [115] studied
sinusoidal microchannel with rectangular cross-section experimentally.
In this study, Microchannels with identical units were developed with an
average width of 205 µm and depth of 404 µm, a wavelength of 2.5 mm,
and an average amplitude of 0 to 259 µm. The heat transfer performance
of wavy microchannels was significantly improved, and the pressure
drop associated with this design was lower than the heat transfer
enhancement for Reynolds numbers ranging from 300 to 800.
To obtain the best thermal performance, many researchers utilized
various optimization methods in terms of heat transfer and pressure
drop. Rostami et al. [109] developed an optimum geometry for a wavy
microchannel in numerical research. They employed the SIMPLE
method with a steady heat flow for the wavy channel. The existence of
the optimal heat transfer condition was associated with the presence of
recirculation zones, secondary flows, and conjugate boundary condi­
tions and their dependence on the Reynolds number and geometrical
parameters. Zhou et al. [116] used response surface methodology (RSM)
in combination with finite volume techniques to determine the optimal
geometry for wavy-wall heat transfer (FVM).
Additionally, they employed a comprehensive heat transfer index to
determine if the benefit of improved heat transfer surpasses the disad­
vantage of increased pressure drop. Heat transfer was enhanced by up to
2.8 times when a wavy channel with a wave amplitude of 40 and a
wavelength of 100 was used. A more effective convective heat transfer
coefficient can be obtained by employing a wavy channel with greater
amplitude and a shorter wavelength. When vortices were generated and
disturbed, a thin boundary layer contributed to the improved heat
transfer. Nemati et al. [117] used a multi-objective genetic algorithm to
improve the geometry of the mini-channel in order to decrease thermal
resistance and pumping power. Subsequently, linear programming
methods for multidimensional preference analysis (LINMAP) were used
for the optimal selection among non-inferior points. The LINMAP
method reduced thermal resistance to 87% of that of a straight channel
with just a 10% increase in pumping power. While a fully wavy channel
had a higher heat resistance, accessing it required high pumping power.
In comparison to previous studies, they used CFD methods being
accompanied by an optimization algorithm while the channel geometry
was not constant along the length.
3.2. Different designs of wavy microchannel
Owing to the high thermo-hydraulic performance of wavy channels,
these channels have been utilized in compact heat exchangers. Effective
parameters in the performance include geometry, channel height, the
aspect ratio of the channel, wave parameters, and phase differences
between wavy walls. Naqiuddin et al. [118] presented a review study on
the design of wavy and straight microchannels for high heat flux thermal
management applications. The most of research demonstrated that
altering the geometry improves heat transfer while increasing pressure
drop. This numerical study investigated a wavy (MC) channel with a
tangential branched secondary channel [119]. This design was exam­
ined to reduce pressure drop by replacing a wavy channel with a
tangentially branched secondary channel on peaks. The result compared
to other designs such as wavy (MC) and wavy MC 45-degree branches
secondary flow. With secondary channel width as half of the primary
channel, the best heat transfer and pressure drop relation could be ob­
tained in comparison to other designs. Flow and heat transfer charac­
teristics in a wavy channel were investigated by Harikrishnan and
9
International Journal of Thermofluids 14 (2022) 100153
Tiwari [120] with different corrugations in a wavy channel: spanwise,
streamwise. They utilized the secondary flow industry (SFI) and the field
synergy principle (FSP). The numerical model considered a range of
wave amplitudes and the number of waves in both streamwise and
spanwise directions for a specific channel width and height. The surface
wave generated streamwise and spanwise vortices that assisted in mix­
ing the fluid, while the corrugations create secondary flow inside the
wavy channel. Finally, a 3D wavy channel performed better than a 2D
wavy channel.
Chiam et al. [121] developed a new wave channel design with sec­
ondary branches in numerical and experimental research. This design
was evaluated for different amplitude and Reynolds numbers ranging
from 50 to 200. The convectional wavy channel demonstrates superior
thermal performance and a greater pressure drop. With decreasing
amplitude, the findings showed better heat transfer while maintaining
the same pressure drop. As a consequence of increasing span-wise fluid
mixing and boundary layer disruption, the creation of dean vortices and
secondary branches indicated the potential to substantially boost
convective heat transfer while imposing smaller pressure drop penalties.
Wang et al. [122] performed numerical simulations to investigate
symmetric and parallel wavy microchannel heat sinks with secondary
branch and Reynolds numbers ranging from 50 to 700. Symmetric
configurations exhibited four dean vorticities at high Reynolds numbers,
resulting in a more significant Nusselt number than parallel configura­
tions with two dean vorticities. Due to the increased pressure drop in
symmetric configuration, this design had a slight disadvantage in terms
of overall performance. However, when a modified microchannel was
used, the pressure drop in a symmetric configuration was reduced, but
the Nusselt number was increased. They proposed a modified symmetric
wavy configuration with a broader difference and a low
amplitude-to-wavelength ratio.
To generate wavy branching channels, Kumar et al. [123] presented
a parametric investigation using three distinct secondary pass configu­
rations of 0.5λ, 1.0 λ, and 1.5 λ (where λ is the wavelength of the wavy
channel, which is equivalent to 20 mm) and employed air as the working
fluid. The impact of secondary pass location was investigated in a
branched wavy mini channel, and the best performance was achieved
for a distance equal to 1.0 λ. Fig.5 shows the fabricated branched wavy
microchannel with a second pass with different locations.
In secondary flow, flow mixing and wall interaction are significant
phenomena. Alihosseini et al. [124] examined two types of wavy
microchannels with oblique groove fin numerically. Secondary flow
induced redevelopment of the thermal boundary layer at each fin in
developing flow. Fig.6. Depicts the schematic of wavy microchannel
heat sink with oblique grooved finned. Fluid flow patterns were
concluded as the most significant cause for efficiency increase. The fluid
velocity was low at the channel’s entrance but surged and produced a
vortex in the center. As a result, the local Nusselt number increased
significantly following the creation of the vortices in the channel’s
midsection. Kim et al. [125] conducted a CFD model to optimize design
parameters in the cross-cut applied wavy fin heat exchanger. Using this
design, flow control was produced by the cross-cut disturbs the thermal
boundary layer and blocked longitudinal heat transfer, resulting in
performance improvement. The heat transfer performance was 23.81%
higher than that of a conventional wavy fin, while the pressure drop rose
by a maximum of 7.04%. In three-dimensional numerical research, the
influence of secondary flow produced by skewness on heat transfer and
flow in a wavy channel was evaluated by Harikrishnan and Tiwari
[126]. Corrugated surfaces were considered a passive method for
enhancing heat transfer area while generating turbulent flow.
Utilizing pin-fins in both straight and wavy miniature heat sinks was
studied by Chamanroy and Aliabadi [127] for wavy and straight
pin-fins, shown in Fig.7. The straight miniature heat sink with straight
pin-fins outperformed the wavy miniature heat sink with wavy pin-fins
with the same spin. Soleymani et al. [128] investigated heat transfer and
pressure drop in a microchannel pin-fin hybrid heat sink utilizing
M. Hajialibabaei and M.Z. Saghir
Fig.5. Fabricated branched wavy microchannel with a second pass with different locations [123].
Fig.6. The schematic of wavy microchannel heat sink with oblique grooved finned [124].
numerical simulations. The hotspot zone was formed by rounded rect­
angular pin-fins and NACA 0024 airfoil pin-fins. Different geometrical
characteristics such as pin-fin shape, pin-fin angle, and wall wave
amplitude were investigated. They found better thermal performance
for pin-fin with rounded edges. Additionally, as the amplitude of the
wall increased, heat transfer increased. The increasing amplitude of the
microchannel’s wavy wall boosted heat transfer, while pressure drop
rose significantly.
Ghani et al. [129] investigated wavy microchannels with sinusoidal
cavities and rectangular ribs numerically for Reynolds numbers between
100 and 800. The arrangement of ribs in the center region of their new
design resulted in a larger flow area, which significantly reduced pres­
sure drop and high flow disturbances. They made use of sinusoidal
cavities on the microchannel’s sidewalls, as well as ribs in the channel’s
center, and optimized geometry for best performance. According to
research, porous ribs can be replaced with solid ribs to minimize
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International Journal of Thermofluids 14 (2022) 100153
pressure drop with a minor reduction in heat transfer. Wang et al. [130]
used a 3D model to examine a novel design of a double layer wavy
microchannel with a porous vertical wave. The result was compared to a
straight microchannel with solid ribs and porous ribs and a wavy
microchannel design with solid ribs. By using porous ribs, pressure drop
could be reduced. Additionally, the wavy channel creates vortices and
improves flow mixing. When the pumping power is between 0.005–0.01
W, the coolant input velocity becomes a more significant influence.
Moreover, they determine the optimal wavelength and amplitude for
pumping power of 0.05 W utilizing single parameter analysis. Porous
ribs reduced pressure drop, whereas wavy channels maximized heat
transfer. They employed the double-layer wavy channel with porous ribs
to enhance thermal resistance, pressure drop, and temperature rise in
the bottom wall. For comparison, constant pumping power was used. Al-
Aabidy et al. [131] used porous metal foam to study turbulent flow in a
wavy channel. When the permeability of the porous layer was reduced,
M. Hajialibabaei and M.Z. Saghir
Fig.7. Different designs of straight and wavy pin-fins in microchannel heat [127].
the repeating flow pattern tended to occur in earlier regions towards
upstream than the flow over a solid wavy surface. Furthermore, when
the wave amplitude and porous layer thickness were raised in the early
area of the wavy section of the channel, the repeating flow pattern
occurred more frequently than when the wave amplitude and porous
layer thickness were low.
Ma et al. [132] investigated the optimization of microchannel heat
sinks with an offset zigzag cavity for Reynolds numbers varying from
200 to 800. The numerical model took into account the entry effect,
viscous heating, and temperature-dependent thermal-physical parame­
ters. Total thermal resistance per pumping power was used to determine
the overall thermal performance. The maximum temperature of the
heating surface was reduced by 5.65 K for Reynolds number equal to 800
while the minimum temperature was raised by 0.36 K, and the pumping
power dropped by 1.4%. Brodnianska et al. [133] presented two new
wavy channel designs: the in-line wavy channel and the offset wavy
channel. They introduced new average Nusselt number correlation
formulae for in-line and offset wavy channels. When Reynolds number
and the channel height were varied, the offset wavy channel achieved a
thermal performance of 5.7–15.7% better than the in-line channel.
Dai et al. [134] examined various microchannel geometries,
including zigzag and sinusoidal paths, for Reynolds numbers ranging
from 50 to 900. According to a complete flow dynamics analysis, the
bend’s flow recirculation and secondary flow structures (Dean vortices)
contributed to enhancing heat transfer rates and considerable
improvement in heat transfer performance over straight channels. The
influence of three wavy channel configurations on a single banked
Printed Circuit Heat exchanger was explored by Aneesh et al. [135] with
the shapes of triangular, sinusoidal, and trapezoidal. In comparison to
sinusoidal, triangular, and straight channel-based PCHE models, the
trapezoidal PCHE model exhibited the greatest heat transfer with the
smallest pressure drop. Heat transfer in a twisted sinusoidal wavy
microchannel was investigated for a fully developed laminar flow.
Twisted wavy microchannels enhanced heat transfer while having lower
pressure drops than the sinusoidal microchannels. Zhang et al. [136]
investigated the effect of amplitude and wavelength on heat transfer in
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International Journal of Thermofluids 14 (2022) 100153
conventional wavy channels and curved, wavy channels in a numerical
simulation. Using the overall curvature parameter improved heat
transfer for wave amplitudes of 0 mm, 0.40 mm, and 0.8 mm. As the
amplitude increased, this boosting impact eventually diminished. In an
experimental study, Spizzichio et al. [137] investigated fluid flow in a
microchannel with different geometries using micro–Particle Image
Velocimetry. They discovered that a serpentine cell achieves the best
efficiency regardless of flow regime, with high Nusselt numbers and
low-pressure losses. To improve the thermal performance of micro­
channel heat sinks, Yuan et al. [138] proposed a non-uniform wavy
microchannel. A flow visualization platform observed the flow behavior.
In a numerical study, Xie et al. [59] studied different types of
microchannels, including straight microchannels, single layer wavy
microchannels, and double-layer wavy microchannels. When the flow
rate increased, the overall thermal resistance of the single-layer
decreased while leading to a growing pressure drop. Using a
double-layer microchannel, both overall thermal resistance and pressure
drop decreased. Shen et al. [139] employed a staggered configuration to
analyze convective heat transfer in a double-layer microchannel
numerically with both parallel and counter flow arrangements. The re­
sults indicated that it is preferable to enhance heat transfer using stag­
gered wavy DMHSs with opposite amplitude. Among the double-layer
wavy channels investigated (the counter flows of straight parallel, and
opposite wavy staggered), the counter flow of straight staggered DMHS
had the highest overall thermal performance while staggered DMHS has
a greater pressure drop and pumping effort. Vaisi et al. [140] evaluated
the effect of geometries on three fluid heat exchangers with wavy and
strip fins in an experimental investigation. Strip channel was used for
hot and cold fluid, and the wavy channel was utilized for condensed
vapor.
Aliabadi and Feizabadi [141] demonstrated a mini channel heat sink
with a combination of straight and wavy wall structures. Different
configurations for this combination are depicted in Fig.8 for a micro­
channel heat sink. The results revealed that switching from a co-current
to a counter-current pattern reduces the maximum temperature differ­
ence at the base of MCHSs substantially. Mini channel heat sinks
M. Hajialibabaei and M.Z. Saghir
Fig. 8. The combination of straight and wavy wall structures with different configurations in microchannel heat sink [141].
(MCHSs) in the straight (S-S-S) and wavy (W-W-W) configurations were
compared to combination (S-W-S and W-S-W) configurations. Both
co-current and counter-current patterns are explored to find the optimal
model with the smallest maximum temperature difference and the
lowest total thermal resistance. The W-W-W model achieved the best
synergy between velocity vectors and temperature isotherms. Pour­
hammati and Hossainpour [142] altered the relative wave amplitude
and wavelength along the microchannel with a Reynolds number of 200
to 1200. At low Reynolds numbers, MCHS could not compete with
traditional wavy MCHS; at higher Reynolds numbers, laminar flow
achieved better heat performance. Thermal resistance was reduced by
up to 18.244% by increasing the relative wavelength and amplitude of
the wave; however, subsequent pressure drops resulted in lower overall
performance. Furthermore, adjusting the wavelength and wave ampli­
tude together produced no noticeable impact, but modifying the wave­
length and wave amplitude independently was more effective.
Tiwari and Moharana [143] evaluated flow boiling in a wavy
microchannel numerically. They compared the boiling of single-phase
and two-phase flow in straight and wavy microchannels. They investi­
gated various characteristics, such as waviness, substrate thickness to
channel height ratio, wall to fluid conductivity, and mass flow. Ma et al.
[144] conducted flow boiling experiments using acetone as the working
fluid in a sinusoidal wave microchannel with secondary channels. A
summary of different designs in the wavy microchannel is presented in
Table 3. In comparison to straight microchannel, studies showed supe­
rior heat transfer performance for wavy microchannel heat sinks due to
span-wise fluid mixing, however, using modified designs can enhance
the heat transfer. The main studies have focused on the geometrical
variables affecting wavy heat sinks. The use of pin-fins to provide sec­
ondary flow exhibited improved performance to other approaches, and
further exploration of alternative shapes and configurations can be
recommended for future investigations.
3.3. Nanofluids in wavy microchannel
Numerous nanofluids have been used in wavy channels enhanced
with altering geometry, including convectional nanofluids (metal, metal
oxide, and carbon-based), hybrid nanofluids, and biological nanofluids.
Using three different nanofluids was investigated by Sakanova et al.
12
International Journal of Thermofluids 14 (2022) 100153
[145] in both straight and wavy microchannels, including Diamond,
CuO and SiO2. They found that as compared to straight channels, wavy
channels can improve heat transfer performance. While the influence of
Nanofluid disappeared the enhancement of wavy design. Moreover, due
to the highest heat transfer coefficient and the lowest thermal resistance
in comparison to other nanofluids, Diamond–water nanofluid ranked the
highest performance. The mixing of fluid with the wavy walls was one of
the effective methods for heat transfer enhancement. The influence of
nanoparticle volume fraction, wavy channel amplitude, and wavelength
on a two-dimensional wavy channel was investigated numerically
[146]. Additionally, the effect of Reynolds number on flow and heat
transfer was explored. Copper-water nanofluid was employed in this
work as working fluids. The volume fraction of nanoparticles, the
amplitude of the wavy wall, and the Reynolds number, rather than the
wavelength, were the most critical factors in improving heat transfer.
Bazdar et al. [147] addressed heat transfer and turbulent flow in a wavy
microchannel with varying sinusoidal wavelengths in a
three-dimensional numerical study. The effect of employing CuO
nanofluid for flow with Reynolds numbers ranging from 3000 to 7500
was explored. They concluded that when Reynolds number was less than
7500, the Nusselt number did not change; however, when Reynolds
number was more significant than 7500, the Nusselt number increased.
Performance evaluation had the highest value, with a volume fraction of
3%. They advocated for the use of nanofluids from an engineering and
economic standpoint.
Rostami et al. [148] evaluated heat transfer in a wavy microchannel
using Al2O3 Nanofluids employing the Eulerian and Lagrangian
methods. They found that the Nusselt number increased in the wavy
wall. Additionally, by boosting nano volume friction, the Nusselt
number increased while pressure drop did not change considerably.
Heat transfer and pressure drop were enhanced by 162.3% and 195.7%,
respectively, when a wavy channel was used instead of a straight
channel. They discovered that using nanofluid resulted in higher pres­
sure drops. The Nusselt number increased by 11.6%, while the pressure
dropped by 2.4% for volume factor 0.02. Because nanofluid improved
heat transfer rates without increasing pressure drop, this design was
preferred for wavy microchannels. Akbarzadeh et al. [149] employed
surface methodology to determine the thermal and pumping power in a
wavy channel flowing with nanofluid. They discovered that the aspect
M. Hajialibabaei and M.Z. Saghir International Journal of Thermofluids 14 (2022) 100153

Table 3 nanofluids in a sinusoidal wavy channel were investigated by Ghasemi

A Summary of different designs in wavy micro-channel. et al. [150]. They found that increasing the thermophoresis resulted in
References Design of wavy Renumber Notable remarks an increase in the values of the temperature distribution. Additionally,
channel Range by decreasing the thermophoresis parameter, the volume percentage of
Chiam et al. Secondary 50- 200 Fluid mixing increases nanoparticles rose.
[121] branches heat transfer while The combination of nanofluids with the enhanced wavy channel can
maintaining a be effective in the thermal performance of the microchannel heat sink.
reasonable pressure Analysis of non-newton nanofluid and rectangular ribs with five
drop.
Wang et al. [122] Secondary branch 50–700 Nu number
different heights in a wavy microchannel was studied by Pahlevani­
enhancements for nezhad et al. [151]. Al2O3 nanoparticles with different volume friction
parallel and wavy and diameters were used as a working fluid mixed with carboxymeth­
arrangements ylcellulose at 0.5%. Moreover, they used different geometry for ribs as
Significant
obstacles in the middle wall of microchannels. Raising the volume
improvement in overall
performance by using a proportion of nanofluid increased the total Nusselt number and the
modified parallel highest obstacle resulted in the maximum friction factor. A branched
configuration wavy channel with Al2O3 Nanofluids as working fluids were developed
Alihosseini et al. Oblique groove 250–850 For fins with a width of by Kumar et al. [152] for Reynolds numbers 100 to 300. This configu­
[124] finned 125 m, a maximum
average Nusselt number
ration enhanced macroscopically mixing and secondary flow. For a 2%
of 80 and a pressure volumetric concentration of nanofluids at Reynolds number equal to
drop of 50 kPa at Re = 300, a 154% increase in heat transfer was observed as compared to a
850 are obtained straight channel.
Kim et al. [125] Cross-cut flow 100–400 Maximum 23.81%
Khan et al. [153] utilized numerical methods to investigate the
control enhancement in heat
transfer performance performance of straight, wavy, and dual wavy Micro-Channel Heat Ex­
Maximum 7.04% changers. They employed laminar aluminum-based nanofluids. For all
increase in pressure channels, increasing the Reynolds number led to a rise in pressure drop.
drop Owing to the existence of secondary vortices, wavy channels and dual
Chamanroy and Straight and wavy 100–1000 Enhancement of the
wavy channels exhibited superior convective heat transfer. Using a dual
Aliabadi [127] pin-fins heat transfer coefficient
by 0.05 to 2.3 times wavy channel with a wavy base structure and 6% nanoparticles resulted
Increase in pressure in a maximum Thermal Performance Factor of 2.2. A wavy mini-channel
drop by 2.6 to 13.6 times with the impulsive flow and Al2O3 Nanofluids were investigated by
The highest
Akdag et al. [154]. Pulsating flow had a positive effect on heat transfer
enhancement was for
wavy pin-fins with enhancement and also reduces sedimentation of nanofluid. As the vol­
opposite spin ume fraction of nanoparticles and the amplitude of pulsation increase,
Ghani et al. Sinusoidal cavities 100–800 At Re = 800, a heat transfer performance rises significantly, whereas the pulsation
[129] and rectangular performance factor of frequencies had a negligible influence. The combined effect of pulsation
ribs 1.8 was obtained with
and nanoparticles on enhancing the Nusselt number was beneficial in
sinusoidal cavities and
rectangular ribs comparison to the steady flow condition.
Ma et al. [132] Offset zigzag 200- 800 The maximum In terms of new types of nanofluids, the use of biological water-silver
grooves temperature decreased nano-fluid in wavy microchannel was investigated by Al-Rashid et al.
from 324.02 to 318.01 K
[155]. They discovered that nanofluids perform better, and also increase
Pressure drop reduced
from 298.81 kPa to
in wavelength enhanced the nanofluid’s hydrothermal performance
27.91 kPa while decreasing the rate of global total entropy creation. Rabiei et al.
Shen et al. [139] Staggered Significant heat transfer [156] investigated the cooling efficiency of a cylindrical microchannel
configuration- enhancement for the heat sink using a hybrid graphene-platinum/water nanofluid as the
double layer staggered wavy channel
working fluid. Ghachem et al. [157] utilized CNT-Al2O3 hybrid nano­
with opposite
amplitude& fluids to further enhance the features of thermal energy exchange while
The counterflow of minimizing pumping power. They demonstrated a modified wavy rect­
straight, staggered angular channel cross-flow micro heat exchanger. A summary of uti­
channels provided the
lizing nanofluids in the different wavy microchannels is provided in
best overall thermal
performance.
Table 4 which shows these investigations examined the characteristics
Aliabadi and Combination of 100–900 The maximum overall of nanofluids and volume fractions in conjunction with geometric pa­
Feizabadi straight and wavy performance of 2.22 for rameters. Some recent modifications in the design of wavy microchannel
[141] wall structures a counter-current addressed in Section 3–2, by the way of illustration using pin-fin, have
pattern at Re = 900
the potential to be accompanied by nanofluids, particularly new hybrid
Pourhammati Relative wave 200- 1200 By adjusting the
and amplitude and wavelength and height, nanofluids.
Hossainpour wavelength the overall performance
[142] was increased to 1.338 4. Application of mini-channel in lithium-ion battery
with a minimum total
resistance of 0.607 K/W
Mini channels encompass a wide range of applications in thermal
management including electric devices, solar panels [17], and batteries
ratio of the channel has a more significant influence on the [18]. Environmental concerns have boosted interest in electric vehicles
non-dimensional pressure drop than either the Reynolds number or the in recent years, however, the primary constraint on this technology is
solid volume fraction. Buongiorno’s model was used to investigate the the thermal management of Lithium-ion batteries. These batteries
convective heat transfer of a nanofluid in a wavy channel with a con­ perform best and have the longest calendar life when utilized between
stant pressure drop. Thermophoresis and Brownian diffusion of 25 and 40 ◦ C [158]. The growth of electric vehicles (EVs) necessitates
complementing battery temperature control solutions. Liquid cooling is

13
M. Hajialibabaei and M.Z. Saghir International Journal of Thermofluids 14 (2022) 100153

Table 4
A Summary of utilizing nanofluids in the different wavy microchannels.
Study Working fluid Re number Concentration Key Remarks
range range

Sakanova et al. [145] CuO and Si2O3 0–5% 100–800 Rather than the wavelength, the volume fraction of nanoparticles, the amplitude of the wavy
wall, and the Reynolds number all contribute significantly to improving heat transfer.
Bazdar et al. [147] CuO 0, 1.5, and 3000–7500 The maximum performance evaluation was achieved for nanofluid flow with a volume
3% fraction of 3%
Rostami et al. [148] Al2O3 0% to 2% – Enhancement of the Nusselt number with increasing volume fraction without a
corresponding rise in pressure drop&162.6% and 195.7% increase in heat transfer rate and
pressure drop compared to a straight channel
Akbarzadeh et al. Cu-water nanofluid – 300–600 Using surface methodology&The maximum 56% enhancement in Nusselt number with an
[149] flows increase in aspect ratio from 0.1 to 0.3 at Re = 60
Pahlevaninezhad et al. Al2O3 0.5% and 5–300 Enhancement of average Nusselt number with increasing the volume fraction&For the
[151]. 1.5% highest obstacle heights Rib heights, the maximum friction factor was achieved
Kumar et al. [152] Al2O3 0.5–2% 100–300 154% enhancement of the heat transfer coefficient with a 2% volumetric concentration at
Re = 300
Akdag et al. [154]. Al2O3 0–6% 100 Enhancement of heat transfer performance by an increase in the volume fraction and the
amplitude of pulsation and insignificant impact of pulsation frequencies
Al-Rashid et al. [155]. Biological water- 0, 0.1, 0.5 300–1500 Increasing the fraction of nanoparticles enhances the heat sink’s performance
silver nano-fluid and 1% An increase in the amplitude of the wavy channel up to 138 μm leads to enhancement in the
PEC
Ghachem et al. [157] CNT-Al2O3 hybrid 0–5% – The maximum efficiency was obtained with a wavenumber of 8 and a nanoparticle
nanofluids concentration of 0.05 at a 50 mm/s inlet velocity

an efficient method of maintaining a battery’s operating temperature
within a restricted optimum range to ensure quick charging/discharging
capacity[158]. Li-ion batteries are present in a range of shapes,
including cylindrical, coin, prismatic, thin, and flat, each of which offers
distinct applications and advantages [160]. The various cooling
methods that have been used for battery thermal management encom­
passed air cooling, direct liquid cooling, fin cooling and indirect liquid
[161]. Numerous researchers have examined the use of mini and
microchannels in the indirect cooling approach. The thermal perfor­
mance of a liquid cooling system in a cylindrical lithium-ion battery was
investigated in an experimental study. The average temperature was
reduced by 43.7% and 47.3% for 1C and 1.5C, respectively, using mini
channel cooling [162]. Kalkan et al. [163] compared the cooling per­
formance of an LFP pouch-type prismatic battery with a conventional
serpentine tube and a microchannel design with a unique surface
structure. Compared to the serpentine design, a micro-channel cold plate
reduced the highest average temperature by 5.7 ◦ C, leading to 40%
more temperature uniformity. The straight mini channel cold plate as a
liquid cooling system for lithium-ion battery temperature management
was investigated by Qian et al. [164]. They investigated the number,
inlet liquid mass flow rate, flow direction, and width of the
mini-channel. At 5C discharge, the mini-channel cold-plate thermal
management system had a high cooling efficiency in managing the
battery temperature.
Moreover, An et al. [165] utilized a straight mini channel for
lithium-ion battery cooling. In an experimental and computational
study, mini-channel cold plates were used by Panchal et al. [166] to
control the heat in prismatic lithium-ion batteries. By increasing the
discharged rate and operating temperature, the temperature of the cold
plate was elevated. The findings provided information for battery sys­
tem design and optimization. Lan et al. [167] proposed a mini channel
with different flow directions for a battery thermal management system
(BTMS) to investigate a single prismatic Li-ion cell at various configu­
rations and discharge rates. They discovered that the mini channel
cooling system was a reasonable option for the BTMS due to its homo­
geneous temperature distribution and efficient pumping power.
Changing design parameters and discharged rates in the mini-
channel cold plate were proposed by Tang et al. [168]. The results
revealed that performance could be enhanced by reducing the input
coolant temperature or raising the flow rate adequately. Monica et al.
[169] employed a rectangular microchannel cold plate for cooling
prismatic batteries, as shown in Fig.9. COMSOL multiphysics was used
to evaluate a variety of factors, including channel number, width,
alternative flow arrangements, and the position of intake and output
ports. The channel with five passages and a width of 4 mm was deter­
mined to be the optimal design in terms of heat transfer and pressure
drop. In a numerical study, Hue et al. [170] evaluated the impacts of the
number of channels, flow direction and ambient temperature on battery
temperature in a mini-channel cold plate. They discovered that the
number of channels and mass flow rate of the inflow have an inverse
relationship with the battery’s maximum temperature. Zhao et al. [171]
conducted a numerical study to investigate the impact of channel
number, mass flow rate, flow direction, and entrance size on the heat
dissipation performance of a unique type of cylindrical battery cooling
system based on a mini-channel liquid-cooled cylinders. They discov­
ered that liquid-cooled cylinder cooling could outperform natural con­
vection cooling in terms of maximum temperature and local
temperature difference only when the channel count exceeds eight.
When the mass flow rate of the input was constant, the heat dissipation
capacity was enhanced first and subsequently decreased as the entry size
increased. Fang et al. [172] experimentally investigated the thermal
performance of a straight mini-channel cold plate in battery thermal
management. Because of the non-uniform velocity distribution between
each channel, increasing the channel number from 3 to 11 increased the

Fig. 9. The schematic of the rectangular micro-channel cold plate for cooling prismatic batteries [169].

14
M. Hajialibabaei and M.Z. Saghir
temperature deviation while having no effect on the cold plate’s average
temperature.
In terms of different configurations, Patil et al. [173] evaluated the
thermal performance of a water-cooled lithium-ion battery cell and pack
using a U-turn type microchannel cold plate. Effective characteristics
such as discharge rate and varying inlet flow and temperature were
investigated for various channel designs and numbers in order to
discover the best cooling strategy. By optimizing the cooling settings, it
was possible to keep the maximum temperature and temperature
non-uniformity of a 50 V battery pack below 40 ◦ C and 4 ◦ C, respec­
tively. Thakur et al. [174] conducted numerical studies on the perfor­
mance of a commercial-size lithium-ion battery pack under various
design and operating circumstances using a lumped capacitance heat
transfer model in conjunction with a flow network approach. A
three-inlet–single-outlet arrangement achieved exceptional perfor­
mance while consuming relatively little pump/compressor power and
dispersing temperature and voltage. U-flow and Z-flow configurations,
on the other hand, have generally been employed in cooling flow net­
works. Siruvuri et al. [175] proposed a new circuitous rectangular
channel to investigate the effect of volume flow rate, flow direction, and
contact area on the cooling of a battery pack consisting of five rectan­
gular cells. Monika and Datta [176] examined 6 mini channels with
Fig. 10. Different designs of mini channel cold plates for the cooling of Lithium-ion batteries [177].
15
International Journal of Thermofluids 14 (2022) 100153
varying configurations focused on a specific battery module, including
serpentine, U-bend, straight, pumpkin, spiral, and hexagonal designs
with a constant channel volume. Temperature homogeneity could be
significantly improved with serpentine and hexagonal designs, while the
pumpkin model preserves a lower pressure drop and pumping power.
Amalesh et al. [177] numerically proposed seven new designs for mini
channel cold plates used to cool Li-ion batteries (such as sine wave
channel, arc channel, and zigzag channel…), As shown in Fig.10. All
layouts outperformed the straight rectangular channel and kept the
battery temperature below 40 ◦ C. Zig-zag and circular slot channels
provided an extraordinarily high cooling capacity.
To enhance thermal management performance, some researchers
concentrated on enhanced micro and mini channels. A novel oblique
mini channel liquid cold plate with continuous straight fins and opti­
mized oblique cuts was developed for cooling EV batteries by Jin et al.
[159]. This design led to the regeneration of boundary layers and
enhanced heat transfer. Consequently, heat transfer in the oblique fin
mini channel was much greater than in a conventional channel. This LCP
maintained the battery’s average surface temperature below 50 ◦ C when
subjected to a 1240 W heat load and 0.9 l/min flow rate. Three con­
figurations for a mini channel liquid cold plate with an oblique fin were
demonstrated, including inline, incline, and louvered [178]. The
M. Hajialibabaei and M.Z. Saghir
average surface temperature of the battery was kept below 50 ◦ C with
this design, and the lowest surface temperature was accomplished with
the louvered arrangement. For cylindrical batteries with straight
microchannels and heat-conducting blocks, a compact liquid cooling
battery thermal management system was presented by Tang et al. [179].
As the gradient angle increased, the temperature uniformity improved;
for example, when the gradient angle is 15◦ , the temperature difference
of the battery module can be adjusted to 8.05 ◦ C. In the numerical
analysis, Ding et al. [180] studied several liquid cooling structures,
including mini channels with circular and square cross-sections.
Compared to the circular channel, the square cross-section form has a
lower temperature. The highest temperature decreased as the aspect
ratio increased, but a significant increase in the aspect ratio increased
temperature dispersion and decreased the uniformity of the thermal
phenomena.
There is a need to improve flow mixing in battery cooling since the
temperature distribution does not follow uniformity while micro­
channels have a regular temperature distribution. Xie et al. [181]
investigated a microchannel liquid cooling arrangement with baffles for
the Tesla Model S battery. Increased heat transfer was accomplished by
incorporating baffles into micro-channels with an acceptable pressure
drop. Fan and Wang [182] developed an optimization design for a new
type of liquid cooling with a branching structure and a coolant collection
of dendritic network channels to create a cooling system with a lower
temperature and a lower pump power. This improved design decreased
the maximum temperature from 52.59 to 39.3 ◦ C. A new battery thermal
management system was proposed by Gue et al. [183], being a
mini-channel cold plate with circular pin fins. They utilized circular pin
fins within straight mini-channels to improve heat transfer performance.
The schematic of pin fin arrangements and battery pack is shown in
Fig.11. By evaluating the overall evaluation of cooling performance,
between different arrangements in terms of the inline scheme and
staggered schemes, microchannel with 4 × 3 staggered arranged pin fins
showed better performance. The efficiency index for vertically arranged
pin fins was 4.54 greater than for horizontally arranged pin fins.
Ling Liu et al. [184] developed a new tree-like mini-channel heat
sink for cooling a single prismatic Li-ion cell due to the high demand for
temperature uniformity in LI-ion batteries. The entrance width and slant
angle of the oblique channels, as well as other characteristics of the mini
channel, were investigated. Optimized mini channel, decreased the
temperature of Li-ion battery to 33.69 ◦ C with 17.99 Pa pressure drop.
Consequently, the performance of a tree-shaped mini channel
Fig.11. The schematic of pin fin arrangements and battery pack [183].
16
International Journal of Thermofluids 14 (2022) 100153
outperformed that of a straight mini channel. Hong et al. [185] con­
ducted a numerical study on heat transfer in microchannel walls with
fractal shaped networks. They found that the redesigned fractal-shaped
microchannel network performs much better in terms of thermal resis­
tance and temperature uniformity. To advance channel structure
development, a numerical analysis was conducted on a stream
line-shaped mini channel in order to optimize system performance
[186]. The pressure distributions of straight and stream-shaped channels
are compared in Fig.12. Temperature uniformity was enhanced effec­
tively and that streamlined shape design achieved a maximum efficiency
of 44.52%.
A numerical study was conducted to determine the effectiveness of
Al2O3 Nanofluid in a mini-channel fluid cold plate for prismatic lithium-
ion batteries [187]. Aluminum nanofluids could help improve temper­
ature decrease while having a negligible influence on temperature uni­
formity. Consequently, nanofluid can be more effective for fluid with
lower thermal conductivity, such as engine oil. A mini channel cold plate
with SiO2 nanofluids was developed by Li et al. [188] to optimize per­
formances. They used Response surface methodology (RSM) with NSGA-
II for optimization. To control the temperature of the battery, Qomi et al.
[189] provided sinusoidal harmonic velocity through a microchannel
filled with a hybrid nanofluid and a constant magnetic field. The sinu­
soidal velocity features had little effect on the heat transfer; however,
the pressure drop was significantly affected. When the amplitude of the
input velocity was altered from 0.3 to 0.9, the pressure amplitude
increased by 20%. Micro-scale cooling was shown to be more advanta­
geous for battery thermal control.
Using phase change slurry in mini channel plate was investigated by
Bai et al. [190] for thermal management in batteries. The optimum
cooling plate structure was discovered utilizing orthogonal Matrix
experimental techniques. The cooling performance of PCS including
20% n-octadecane microcapsules and 80% water was compared with
other fluids, for flow rates lower than 3 × 10− 4 kg/s. Results showed
superior performance rather than pure water, mineral oil, and glycol
solution. PCS’s physical characteristics and flow rate can be approxi­
mated using an empirical formula presented by them. In terms of phase
change material features, channel number, and flow rate, a combination
of PCM and microchannels for battery temperature management was
examined by Rao et al. [191]. The maximum temperature decreased as
the number of channels increased.
Akbarzadeh et al. [192] proposed a novel liquid cooling plate with
phase change material to reduce the weight of the cooling plate and
M. Hajialibabaei and M.Z. Saghir International Journal of Thermofluids 14 (2022) 100153

Fig.12. The pressure distributions of straight and stream-shaped channels at a mass flow rate of 0.002 kg/s [186].

increase the overall energy efficiency of the cooling system. Compared
to aluminum LCP, using a hybrid LCP could reduce the pump’s energy
consumption required to circulate the coolant by up to 30%. Mousavi
et al. [193] used a combination of PCM (n-eicosane) and a mini channel
to increase latent thermal capacity of batteries for cooling, being named
s hybrid minichannel cold plates, as depicted in Fig.13. They investi­
gated battery orientation regarding the non-behavior of the battery’s
conduction coefficient. The temporal averages of the highest battery
temperature were much lower than the values employing mini channel
plate cooling. In contrast to previous research that employed a constant
heat flow, this work studied two variables of constant and pulsed heat
flux. The high potential of PCM in the thermal management of batteries
with a microchannel heat sink requires further investigation. Although
several microchannel investigations on microchannel heat sinks have
been performed, future design work can focus on microchannel heat
sinks equipped with heat transfer enhancement methods to create sec­
ondary flow while having practical application.
5. Conclusions
This review summarizes experimental and numerical work on
microchannel heat sinks with two distinct designs: straight and wavy
microchannel. Numerous effective parameters are associated with
microchannel thermal performance. By utilizing various designs as

Fig. 13. The schematic of the mini-channel cold plate and the cut-section of s hybrid mini-channel cold plates [193].

17
M. Hajialibabaei and M.Z. Saghir
passive and active techniques, the overall performance of microchannels
can be improved, which is discussed in two sections. Moreover, using
multiple types of nanofluids as coolants is evaluated for both micro­
channels. The succeeding section consists of applying microchannels in
lithium-ion battery thermal management. The accompanying conclu­
sions are drawn from the review:
• Straight microchannel performance is influenced by a range of
characteristics; including channel height, channel width, inlet, and
outlet configurations. Numerous academics have on optimizing ge­
ometry using machine learning, finite volume techniques, the
Taguchi-Gray method, and multi-objective genetic algorithms.
• Sectional oblique fins with varying angles and pitches, various
shapes of pin fins, and solid and porous ribs proved more effective in
redeveloping the boundary layer in straight micro channel heat sinks
and increased heat transfer with acceptable pressure drop. Moreover,
diverging cross-section and staggered structure in a double-layer
microchannel, as well as an open microchannel heat sink,
improved temperature uniformity.
• Secondary flow (dean vortices) in wavy microchannels leads to
chaotic advection, enhancing heat transfer performance. Thus,
wavelength, amplitude, and phase angle directly affect the flow
pattern, which can be optimized by various techniques, including
SIMPLE methods, response surface methodology, and finite volume
techniques.
• Utilizing secondary branch, straight and wavy pin-fin, sinusoidal
cavities and rectangular ribs, offset, double-layer microchannel,
different shapes of paths, and combination of straight and wavy wall
structures were investigated extensively in a variety of different
designs to strengthen flow mixing and overall thermal performance.
• Due to the effectiveness of nanofluids in improving heat transfer, a
diversity of nanofluids have been used in straight and wavy micro­
channels, including convectional nanofluids (metal, metal oxide, and
carbon-based), hybrid nanofluids, and biological nanofluids. Using
new nanofluids was accompanied by modified designs for micro­
channel heat sink and pulsing flow, engendered to increase in Nusselt
number.
• Microchannels have been utilized for the thermal management of
lithium batteries using indirect liquid cooling methods. Micro­
channels cold plates were employed depending on the battery type
with varying channel numbers, channel shapes, inlet, and outlet
configurations, and flow direction. Moreover, oblique fin, cylindrical
pin-fin, porous media, and nanofluid were studied to decrease the
maximum temperature. However, there are limited studies exam­
ining the use of modified microchannels for indirect cooling
methods.
The following challenges and areas of research need to be explored
further:
• The impact of different configurations of pin-fin should be accom­
panied by investigation of the optimized shape of pin-fins in micro
channel heat sinks.
• Besides geometric analysis, the utilizing secondary flow in modified
wavy channel heat sink in combination with new hybrid nanofluids
should be compared to the same design in a straight channel in terms
of pumping power and heat transfer.
• Nanofluids and secondary flow can be used to promote heat transfer
in the thermal management of lithium batteries with microchannel
heat sinks
• Ambient temperature has a direct influence on lithium battery per­
formance and should be taken into account while designing and
optimizing.
• It is necessary to assess the cooling performance of lithium batteries
under transient or pulsating heat flux.
18
International Journal of Thermofluids 14 (2022) 100153
Declaration of Competing Interest
The authors declare that they have no known competing financial
interests or personal relationships that could have appeared to influence
the work reported in this paper.
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