IN-24-C050 - Numerical Analysis of Forced Convection in an Open-Cell Metal Foam Used in Compact Heat Exchangers Using Fin Theory and Porous Media Approach

A novel approach of using fin theory to study the single phase forced convective behavior in foams is presented and contrasted with the validity of using the porous media approach to metal foams. A 10ppi foam made of aluminum is considered, and the computational simulations are based on the mapped 3D model (µ-CT scan) of its respective structure. A refined poly hex core volume mesh is generated for a small sub sample of the actual foam core with porosity 0.89. Forced convection of air flow is considered, and the computational results are compared, contrasted, and validated with representative and corresponding experimental data of the actual foam sample subjected to similar conditions. The presented results highlight the influence of foam structure and the veracity of using the fin theory to study and analyze foams. The local convective behavior shows the wall effects and its contribution to the overall pressure drop and heat transfer. Moreover, it is found that fin theory provides a much better agreement with the actual experimental data in comparison with the porous media model.