Numerical Simulation of Heat Transfer in Porous Metals for Cooling Applications

Porous metals have low densities and novel physical, mechanical, thermal, electrical, and acoustic properties. Hence, they have attracted a large amount of interest over the last few decades. One of their applications is for thermal management in the electronics industry because of their fluid permeability and thermal conductivity. The heat transfer capability is achieved by the interaction between the internal channels within the porous metal and the coolant flowing through them. This paper studies the fluid flow and heat transfer in open-cell porous metals manufactured by space holder methods by numerical simulation using software ANSYS Fluent. A 3D geometric model of the porous structure was created based on the face-centered-cubic arrangement of spheres linked by cylinders. This model allows for different combinations of pore parameters including a wide range of porosity (50 to 80 pct), pore size (400 to 1000 µm), and metal particle size (10 to 75 µm). In this study, water was used as the coolant and copper was selected as the metal matrix. The flow rate was varied in the Darcian and Forchheimer’s regimes. The permeability, form drag coefficient, and heat transfer coefficient were calculated under a range of conditions. The numerical results showed that permeability increased whereas the form drag coefficient decreased with porosity. Both permeability and form drag coefficient increased with pore size. Increasing flow rate and decreasing porosity led to better heat transfer performance.