Thermal and Fluid Flow Performance Optimization of a Multi-Fin Multi-Channel Cooling System for PEMFC Using CFD and Experimental Validation

Efficient thermal management is critical for sustaining the performance and durability of Proton Exchange Membrane Fuel Cells (PEMFCs), where excessive operating temperatures accelerate material degradation and reduce power output. Previous studies have explored various cooling channel designs; however, limited research integrates zigzag multi-fin geometries with both computational and experimental validation for fin width optimization under high-velocity cooling. This study presents a combined Computational Fluid Dynamics (CFD) simulation using ANSYS Fluent and experimental investigation of a multi-fin multi-channel cooling system for PEMFCs. The effects of fin widths (0.3–1.0 mm), inlet flow velocities (0.6–3.0 m/s), and cooling media (air, 20% ethylene glycol (EG) solution) were analyzed with respect to cathode surface temperature, power density, and cooling efficiency. Results show that a 0.3 mm fin width with 3.0 m/s inlet velocity reduced the cathode temperature by ~13 K and increased power density by ~40%. The optimized zigzag configuration improved heat transfer uniformity, achieving cooling efficiencies up to 67.0%. Experimental validation confirmed the CFD results with less than 3% deviation. The findings highlight the potential of optimized multi-fin designs to enhance PEMFC thermal stability and electrical output, offering a practical approach for advanced fuel cell thermal management systems.