Experimental and numerical analysis of pressure drop optimization and comparative evaluation of multilayer microchannel nanofluid coolants for enhanced thermal performance in compact heat sinks

This research examines the thermal behavior of Al₂O₃-based nanofluids in multilayer microchannel heat sink (MCHS) using both simulation and experimental approaches. The examinations were carried out considering three distinct nanofluid concentrations viz 0.5, 1.0, and 2.0% volume and mass flux values from 0.01 to 0.05 kg/s. Observations demonstrated that an increase in concentration enhances heat transfer performance, with Nusselt numbers ranging 112.0 at 2.0% concentration results, considering that the influence of mass flow rate on the heat dissipation coefficient rose sharply and heat transfer coefficient reached the maximum of 270.8 W/m²·K. As a consequence of it, the pressure drop that accompanied enhanced performance increased to 600 Pa in similar circumstances. This work optimizes Al₂O₃ nanofluids in multilayer MCHS, boosting heat transfer to 270.8 W/m²·K while controlling pressure drop. The optimal 1.5% concentration at 0.04 kg/s offers efficient, scalable cooling solutions for electronics, automotive, and industrial applications. This research also utilized a multi-objective optimization strategy that determined proper operating conditions that would result in both thermal efficiency and pumping power. From these findings, it is evident that Al₂O₃ nanofluids can be used in enhanced cooling applications, and researchers and engineers in the industrial and manufacturing sectors can use them in enhancing their cooling systems designs and parameters.