Study on the flow and heat transfer characteristics inside high-porosity open-cell copper foams: Experimental and numerical explorations

A metal foam with an open-cell structure is a type of material with low flow resistance, high specific surface area, and strong fluid mixing ability. Open-cell metal foams have broad application prospects in electronic component cooling, multiphase heat exchangers, and compact heat exchangers for aerospace applications. This paper presented experimental and numerical analyses of the flow and heat transfer characteristics of five different copper foams under forced air convection. The pores per inch (PPI) of selected foams were 10, 20, 30, 40, and 60, with porosities ranging from 0.968 to 0.973. Analysis of the collected heat transfer and pressure drop data yielded the overall heat transfer coefficient, unit pressure drop, normalized average wall temperature, inertia coefficient, and resistance coefficient. The influence mechanisms of the porosity and flow velocity on heat transfer were analyzed and discussed. The numerical simulation and experiment fitted well. The results showed that increasing porosity led to a significant increase in heat transfer coefficient and unit pressure drop. The 60 PPI foam brought the maximum pressure drop while achieved the minimum thermal resistance.