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@article{202637,
        author = {Hamda Arshad and Fizza Hasan and Ghazi Jamal Khan and Mohd Umar and Sabah Khan},
        title = {Design and Analysis of Functionally Graded Materials for Enhanced Thermal Dissipation in EV Battery Packs},
        journal = {International Journal of Innovative Research in Technology},
        year = {2026},
        volume = {12},
        number = {12},
        pages = {12634-12646},
        issn = {2349-6002},
        url = {https://ijirt.org/article?manuscript=202637},
        abstract = {Electric vehicle (EV) battery packs generate significant heat during charge–discharge cycles, and excessive temperature rise leads to reduced efficiency, accelerated cell aging, and the risk of thermal runaway. This paper presents the design and finite-element analysis of an aluminum–alumina Functionally Graded Material (FGM) intended for use as a thermal-interface and casing element in EV battery packs. A three-dimensional CAD model of a prismatic battery-pack enclosure was developed in SolidWorks, with the FGM stack idealised as five concentric layers of progressively varying composition between pure aluminum and pure alumina. Steady-state thermal and coupled thermo-mechanical analyses were carried out in ANSYS Workbench 2023 R1 across five geometric configurations in which total stack thickness (2.5–7 mm), individual layer thicknesses, and the type of boundary condition (direct temperature versus convection) were systematically varied. The thermal simulations show a strongly non-linear through-thickness gradient with the temperature drop concentrated in the alumina-rich layers; the structural simulations show that peak von-Mises stress (94.1–111.1 MPa) consistently occurs on the aluminum hot face and that an architecture with a thicker alumina bottom layer minimises this peak while keeping all stresses well within the elastic regime of both constituents. The proposed FGM design therefore offers a passive, lightweight, and reliable alternative to active cooling for next-generation EV battery thermal management. Future work will extend the analysis to transient drive-cycle loading, vibration response, and experimental validation of an additively manufactured prototype.},
        keywords = {Functionally Graded Materials; EV battery pack; thermal management; ANSYS; SolidWorks; aluminum–alumina; finite element analysis; thermal stress.},
        month = {May},
        }