Thermal–Fluid Behavior and Heat-Transfer Enhancement in PEMFC Cooling Plates Using Multi-Fin Zigzag Channels Under Variable Slope Angles

Effective thermal management is critical for sustaining the performance, durability, and stability of a proton exchange membrane fuel cell (PEMFC). A thorough numerical investigation of six multi-fin zigzag cooling-channel geometries operating under three slope angles (75°, 90°, and 120°) is presented to monitor the combined impact of geometric complexity and channel inclination on cooling performance. In addition, temperature fields, velocity distributions, localized heat flow, total heat removal, and cooling efficiency were reviewed to characterize thermal–fluid behavior of the individual configuration. The results showed that geometric refinement had the strongest influence on cooling performance, with Type 5 (a = 2, b = 4, h = 2) and Type 6 (a = 4, b = 4, h = 2) progressively achieving declining temperature distributions, greater outlet velocities, and modified coolant mixing. Slope angles also affected flow behavior, where reduced inclination extended coolant residence time and elevated inclination intensified secondary flows, although the influence was secondary to geometry. Total heat flow, area-specific heat extraction, and cooling efficiency were highest in Type 5 (a = 2, b = 4, h = 2) and Type 6 (a = 4, b = 4, h = 2), with Type 5 exhibiting an optimal balance between flow disturbance and hydraulic resistance. This study generally presented practical design guidance for next-generation PEMFC cooling systems, proving that optimized multi-fin zigzag channels significantly advanced thermal uniformity and heat-transfer effectiveness under diverse operating conditions.