Vibration-Aware Topology Optimization of Vanadium Redox Flow Battery Flow Fields: A Computational and Experimental Study on Fluid-Structure Dynamics

Research objectives：

This project aimed to develop and validate an integrated computational framework for the design of flow fields in Vanadium Redox Flow Batteries (VRFBs) that simultaneously optimizes electrochemical performance and mitigates flow-induced vibration (FIV). Specific objectives included:

1. To develop a topology optimization framework capable of generating interdigitated flow channel designs that maximize vanadium species reaction rates while implicitly controlling structural vibration.
2. To model fluid-structure interaction in porous electrodes using a coupled CFD-FEM approach based on the Brinkman formulation and velocity-dependent mass transfer.
3. To experimentally validate the optimized flow field designs through vibration, acoustic, and flow field measurements on a laboratory-scale VRFB test rig.
4. To characterize the dynamic response of optimized vs. baseline designs, quantifying improvements in vibration amplitude, spectral content, acoustic emissions, and structural modal behavior.
5. To establish correlations between flow features (vorticity, velocity gradients, vortex shedding) and vibrational hotspots, providing insight into FIV mechanisms.
6. To propose a design methodology that enhances both electrochemical efficiency and machinery reliability, supporting quieter, longer-lasting energy storage systems.

Keywords：

• Topology optimization
• Flow-induced vibration (FIV)
• Fluid-structure interaction
• Structural dynamics
• Computational fluid dynamics (CFD)
• Redox flow battery design
• Dynamic stability analysis
• Porous electrode modeling
• Vibration mitigation
• Acoustic noise reduction
• Operational modal analysis
• Energy storage reliability

 

Methodology Overview

• Modeling: 2D porous electrode model with Carman–Kozeny permeability, Brinkman flow equations, and adjoint-based topology optimization.
• Simulation: COMSOL Multiphysics® with FEM, Method of Moving Asymptotes (MMA) for optimization.
• Experimental Setup: Lab-scale VRFB with accelerometers, microphones, pressure transducers, and Particle Image Velocimetry (PIV).
• Validation: Comparison of numerical and experimental vibration spectra, modal analysis, and flow field visualization.

 

Key Findings

• 41% reduction in RMS vibration velocity.
• 6.2 dB reduction in A-weighted sound pressure level.
• 23% increase in average reaction rate without significant pressure drop increase.
• Shift in dominant vibration frequency from 254 Hz to 187 Hz.
• Strong correlation between vorticity reduction and vibration suppression.

 

Implications for Industry

• Provides a CAE-driven workflow for designing quieter, more reliable VRFBs.
• Demonstrates dual optimization of electrochemical and mechanical performance.
• Supports integration of renewable storage in noise-sensitive environments.
• Extendable to pumps, turbines, heat exchangers, and other FIV-prone systems.

 

Project Code : VRFB-FIV-OPT

Duration : 01 January, 2026-30 June, 2027

Funding: Deanship of Scientific Research, Taif University (Grant No. 83)

 

Expected Outcomes：

Academic: Peer-reviewed publications

Co-academic leads：

 

 

 

Researcher：