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<p>Immersion cooling technology is promising in achieving sufficient cooling performance for advanced manufacturing, yet its widespread adoption is hindered by uncertainties in long-term material-compatibility and reliability. This study systematically reviews the interfacial interactions between IT/ lithium-ion battery (LIB) materials and components and immersion cooling fluids, focusing on evaluation methodologies and compatibility criteria. The review encompasses three key aspects, including the immersion test protocols (e.g., accelerated conditions at 0–155 °C for durations up to 4 years), physicochemical property analysis of materials/components (e.g., surface/interface appearance, mass/volume/density change, mechanical/electrical properties), and fluid property evaluation (e.g., composition, acid number, viscosity, breakdown voltage). Existing standards for electric vehicle coolants (GB 29743.2) and other material-fluid interactions (e.g., ASTM D3455, ISO 1817) are adapted, but tailored protocols for immersion cooling remain lacking. Through which, the interfacial interactions between materials and immersion cooling fluids were comprehensively analyzed. Detailed evaluations on the changes in different properties of materials, components and coolants after immersion test revealed that the material/fluid compatibility depends on their composition and purity, with slight property variations observed in most cases (e.g., color changes, viscoelasticity fluctuations). However, incompatible scenarios are identified as well. Rubber materials (silicone, NBR, FKM) and plastics (ABS, PS, PVC) show poor compatibility with ester/hydrocarbon fluids, while metals (Cu, Al) exhibit corrosion risks under specific conditions. The study highlights the need for standardized criteria based on long-term field data. This work provides a comprehensive framework for developing reliable immersion cooling fluids and selecting compatible materials, addressing critical gaps in evaluation methodologies and paving the way for practical applications of immersion cooling technology in data centers and LIB systems. Finally, the limitations of current studies are summarized and the potential future research directions and applications are analyzed.</p> Graphical Abstract <p></p>

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The interfacial interactions between materials and immersion cooling fluids for advanced manufacturing: evaluation methodology and compatibility

  • 期刊论文

  • 出版模式：

    开放获取

  • 发表日期：

    2026年7月22日

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  • Xiaojun Zhang,
  • Pengyu Cai,
  • Chunfeng Zhang,
  • Liyang Wang,
  • Shengjuan Li,
  • Xiangqiong Zeng,
  • Yu Zhang,
  • Li Zhang

摘要

Immersion cooling technology is promising in achieving sufficient cooling performance for advanced manufacturing, yet its widespread adoption is hindered by uncertainties in long-term material-compatibility and reliability. This study systematically reviews the interfacial interactions between IT/ lithium-ion battery (LIB) materials and components and immersion cooling fluids, focusing on evaluation methodologies and compatibility criteria. The review encompasses three key aspects, including the immersion test protocols (e.g., accelerated conditions at 0–155 °C for durations up to 4 years), physicochemical property analysis of materials/components (e.g., surface/interface appearance, mass/volume/density change, mechanical/electrical properties), and fluid property evaluation (e.g., composition, acid number, viscosity, breakdown voltage). Existing standards for electric vehicle coolants (GB 29743.2) and other material-fluid interactions (e.g., ASTM D3455, ISO 1817) are adapted, but tailored protocols for immersion cooling remain lacking. Through which, the interfacial interactions between materials and immersion cooling fluids were comprehensively analyzed. Detailed evaluations on the changes in different properties of materials, components and coolants after immersion test revealed that the material/fluid compatibility depends on their composition and purity, with slight property variations observed in most cases (e.g., color changes, viscoelasticity fluctuations). However, incompatible scenarios are identified as well. Rubber materials (silicone, NBR, FKM) and plastics (ABS, PS, PVC) show poor compatibility with ester/hydrocarbon fluids, while metals (Cu, Al) exhibit corrosion risks under specific conditions. The study highlights the need for standardized criteria based on long-term field data. This work provides a comprehensive framework for developing reliable immersion cooling fluids and selecting compatible materials, addressing critical gaps in evaluation methodologies and paving the way for practical applications of immersion cooling technology in data centers and LIB systems. Finally, the limitations of current studies are summarized and the potential future research directions and applications are analyzed.

Graphical Abstract