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An open-cell metal foam has excellent characteristics such as low density, high porosity, high specific surface area, high thermal conductivity, and low mass due to its unique internal three-dimensional network structure. It has gradually become a new material for enhanced heat transfer in industrial equipment, new compact heat exchangers, microelectronic device cooling, etc. This research established a comprehensive three-dimensional structural model of open-cell metal foams utilizing Laguerre–Voronoi tessellations and employed computational fluid dynamics to investigate its flow dynamics and coupled heat transfer performance. By exploring the impact of foam microstructure on flow resistance and heat transfer characteristics, the study provided insights into the overall convective heat transfer performance across a range of foam configurations with varying pore densities and porosities. The findings revealed a direct correlation between convective heat transfer coefficient (h) and pressure drop (ΔP) with increasing Reynolds number (Re), accompanied by notable changes in fluid turbulence kinetic energy (e) and temperature (T), ultimately influencing heat transfer efficiency. Furthermore, the analysis demonstrated that alterations in porosity (ε) and pore density significantly affected unit pressure drop (ΔP/L) and convective heat transfer coefficient (h). This study identified an optimal configuration, highlighting a metal foam with a pore density of 20 PPI and a porosity of 95% as exhibiting superior overall convective heat transfer performance. [ABSTRACT FROM AUTHOR]

Various researchers in the field of engineering have used porous media for many years. The present paper studies heat enhancement using two different types of porous media. In the first type, porous metal foam media was used experimentally and numerically for heat extraction. The porous medium was replaced with a porous structure using the Gyroid model and the triply periodic minimum surfaces technique in the second type. The Darcy–Brinkman model combined with the energy equation was used for the first type, whereas Navier–Stokes equations with the energy equation were implemented for the second type. The uniqueness of this approach was that it treated the Gyroid as a solid structure in the model. The two types were tested for different heat fluxes and different flow rates. A comparison between the experimental measurements and the numerical solution provided a good agreement. By comparing the performance of the two types of structure, the Gyroid structure outperformed the metal foam for heat extraction and uniformity of the temperature distribution. Despite an 18% increase in the pressure drop in the presence of the Gyroid structure, the performance evaluation criteria for the Gyroid are more significant when compared to metal foam. [ABSTRACT FROM AUTHOR]

The purpose of this work is to present a convenient design approach for metal hydride reactors that meet the specific requirements for hydrogen storage. Three methods from the literature, the time scale, the acceptable envelope, and the reaction front, are used to estimate the maximum thickness of the bed allowing for sufficient heat transfer. Further heat transfer calculations are performed within the framework of standardized heat exchanger via the homemade design software, to generate the complete geometry and dimensions of the reactor. LaNi5 material packed in tubular units based on conventional shell-and-tube heat exchanger is selected for analysis for an expected charging time of 500 s, 1000 s, and 1500 s. Apparently, the smaller the expected charging time, the smaller the bed thickness and hence the diameter of the tubular units. After comparison, the method of reaction front was adopted to output standard tube diameters and calculate the weight of the reactor. Significant weight differences were found to result from the varying wall thickness and number of tubes. In general, the shorter the expected charging time, the more tubular units with a small diameter will be built and the heavier the reactor. Fluent 2022 R2 was used to solve the reactor model with a tube diameter of 50 mm supposed to fulfill a charging time of 1500 s. The simulation results revealed that the reaction fraction reaches its maximum and the hydrogen storage process is completed at 500 s. However, because the calculation is conducted on meeting the heat exchange requirements, the average temperature of the bed layer is close to the initial temperature of 290 K and stops changing at 1500 s. The applicability of the method to the design of metal hydride reactors is thus confirmed by the temperature and reaction fraction judgment criteria. [ABSTRACT FROM AUTHOR]

Conventional liquid cooling techniques may provide effective chip cooling but at the expense of high pumping power consumption. Considering that there is dynamic heat load in practice, a self-adaptive cooling technique is desired to reduce operational costs while preserving inherent cooling effectiveness. In this work, a novel self-adaptive cooling strategy is presented to balance the thermal and flow efficiency in accordance with the dynamic thermal load, based on temperature-regulated movement of the metal pillar array in a microfluidic channel. With an illustrative device, the effectiveness of such a strategy is investigated using multiphysics modeling and simulation. As a case study, the device is considered to be initiated with a chip power of 5 W and an inlet coolant velocity of 0.3 m/s. It is shown that the temperature-regulated movement of the metal pillar heat sink will be activated rapidly and equilibrate within 30 s. Parts of the metal pillars immerse into the coolant flow, resulting in significantly improved heat transfer efficiency. The diminished thermal resistance leads to a reduction in chip temperature rise from 225 K (without structural adaptation) to 91.86 K (with structural adaption). Meanwhile, the immersion of metal pillars into the coolant also causes an increased flow resistance in the microfluidic channel (i.e., pressure drop increases from 859.27 Pa to 915.98 Pa). Nevertheless, the flow resistance decreases spontaneously when the working power of the chip decreases. Comprehensive simulation has demonstrated that the temperature-regulated structure works well under various conditions. Therefore, it is believed that the presented self-adaptive cooling strategy offers simple and cost-effective thermal management for modern electronics with dynamic heat fluxes. [ABSTRACT FROM AUTHOR]

The thermal performance of a lithium-ion battery module comprising three cells contained within a casing was investigated at discharge rates of 3C and 5C with three different cooling strategies: forced air, phase-change material (PCM), and a hybrid system using a combination of forced air and the PCM. Three levels of fan speed (5000 rpm; 7000 rpm; and 9000 rpm) for cooling air flow were considered. A numerical simulation of heat transfer was performed using the ANSYS Fluent software. The electrochemical modelling of a battery was developed based on the NTGK approach, and the phase-change phenomenon was treated as an enthesis–porosity problem. The composite PCM, aluminum metal foam embedded in n-octadecane, had better heat dissipation performance than forced air convection. The PCM is significantly more effective at heat dissipation than forced air. Interestingly, when using a hybrid cooling system that combines forced air and a PCM, although it meets the operational requirements for Li-ion batteries in regard to maximum temperature and temperature uniformity at a 3C discharge rate, the airflow appears to have a negligible effect on thermal management and yields an indiscernible change in temperature. This can be attributed to a complex flow pattern that developed in a casing as a result of the suboptimal design of the inlet and outlet. Further studies will be required for the optimal positioning of the inlet and outlet, as well as the effectiveness of combining liquid cooling methods. [ABSTRACT FROM AUTHOR]

The use of innovative methods for the design of heating, cooling, and heat storage devices has been mainly oriented in the last decade toward the use of nanofluids, metal foams coupled with working fluids, or phase change materials (PCMs). A network of nine Italian universities achieved significant results and innovative ideas on these topics by developing a collaborative project in the last four years, where different approaches and investigation techniques were synergically employed. They evaluated the quantitative extent of the enhancement in the heat transfer and thermal performance of a heat exchanger or thermal energy storage system with the combined use of nanofluids, metal foams, and PCMs. The different facets of this broad research program are surveyed in this article. Special focus is given to the comparison between the mesoscopic to macroscopic modeling of heat transfer in metal foams and nanofluids, as well as to the experimental data collected and processed in the development of the research. [ABSTRACT FROM AUTHOR]

A convective stability analysis of the flow in a vertical fluid-saturated porous slab made of two layers with different thermophysical properties is presented. The external boundaries are isothermal with one of them impermeable while the other is open to an external fluid reservoir. This study is a development of previous investigations on the onset of thermal instability in a vertical heterogeneous porous slab where the heterogeneity may be either continuous or piecewise as determined by a multilayer structure. The aim of this paper is investigating whether a two-layer structure of the porous slab may lead to the onset of cellular convection patterns. The linear stability analysis is carried out under the assumption that one porous layer has a thermal conductivity much higher than the other layer. This assumption may be justified for the model of a heat transfer enhancement system involving a saturated metal foam. A flow model for the natural convection based on Darcy's momentum transfer in a porous medium is adopted. The buoyancy-induced basic flow state is evaluated analytically. Small-amplitude two-dimensional perturbations of the basic state are introduced, thus leading to a linear set of governing equations for the disturbances. A normal mode analysis allows one to formulate the stability eigenvalue problem. The numerical solution of the stability eigenvalue problem provides the onset conditions for the thermal instability. Moreover, the results evidence that the permeability ratio of the two layers is a key parameter for the critical conditions of the instability. [ABSTRACT FROM AUTHOR]

The performance of an electronic radiator filled with metal foam with a porosity of 96% was studied. The effect of the factors including the flow rates, the pores per linear inch (PPI) and the numbers of fins was analyzed. The results show that the electronic radiator with metal foam reflects a stronger ability of the heat transfer compared to the electronic radiator without metal foam. With the increase in the flow rate between 10 L/h and 60 L/h, the heat transfer coefficient of both of the two electronic radiators will be improved, but it is also dependent on the number of fins. In this study, we find that the heat transfer coefficient first increases and then decreases with the number of fins. The optimum number is three. As for the effect of the PPI, the higher the PPI, the larger the heat transfer coefficient, while the pressure drop always increases with the flow rates' increase, the pores per linear inch (PPI) and the numbers of fins. [ABSTRACT FROM AUTHOR]

Recent trends in hydrogen production include using renewable energy sources, e.g., biogas as feedstocks for steam reforming. Crucial to the field is minimizing existing reforming reactors for their applications to fuel cell systems. Here, we present a novel design of a steam reforming reactor for an efficient biogas conversion to hydrogen. The design includes a radial division of the catalytic insert into individual segments and substituting parts of the catalytic material with metallic foam. The segment configuration is optimized using a genetic algorithm to maximize the efficiency of the reactor. Changes in the catalytic insert design influence the thermal conditions inside the reactor, leading to moderation of the reaction rate. This article presents a promising approach to producing hydrogen from renewable sources via steam reforming. A significant enhancement in the reforming process effectiveness is achieved with a notable decrease in the amount of the catalyst used. The final results demonstrate the capability for acquiring a similar level of biogas conversion with a 41% reduction of the catalytic material applied. [ABSTRACT FROM AUTHOR]

Thermal abuse of lithium-ion batteries (LIBs) leads to the emission of gases, solids, fires and/or explosions. Therefore, it is essential to define the temperatures at which key events occur (i.e., CID activation, venting, and thermal runaway (TR)) and to identify the related emissions for identifying the hazards to which people and especially rescue teams are exposed. For this purpose, thermal abuse tests were performed on commercial lithium nickel cobalt aluminum oxide (NCA) 18650 cells at 50% state of charge in a reactor connected to an FT-IR spectrometer by varying test conditions (feed gas of N2 or air; heating rates of 5 or 10 °C/min until 300 °C). In particular, the concentrations of the gases and the composition of the condensed-phase emissions were estimated. As regards gases, a high concentration (1695 ppmv) of hydrofluoric acid (HF) was measured, while the emissions of condensed matter consisted of organic compounds such as polyethylene oxide and paraffin oil, and inorganic compounds containing Li (0.173 mg/m3) and Al (0.344 mg/m3). The main safety concerns were caused by the temperatures (564 ± 85 °C) reached by the cell during TR, by the HF concentration which exceeded the toxicity limits of 30 ppm, the IDLH defined by the NIOSH, and the diameter of the particles (1.54 ± 0.69 µm) that rose the PM2.5 concentration. These results are also useful for identifying personal protection equipment for rescue teams. [ABSTRACT FROM AUTHOR]

Significant efforts have explored the field of Phase Change Materials (PCMs) for various applications. Research and real-world applications explore length scales that range from infrastructure to micro systems. A commonality of these efforts is the desire to utilize the phase change capability of the PCM to provide a steady temperature heat sink for thermal storage. Smaller scale efforts and materials are presented in this present review. A general challenge to the use of these PCMs regardless of application is the low thermal conductivity present as a baseline material property. Efforts to improve thermal conductivity have included the addition of underlying metal foam structures, heat pipes, or metallic fins inserted into the base PCM. Other efforts have investigated alterations to the base materials themselves by employing additives such as graphite to supplement thermal performance. Other additives are used to obtain form stability in the PCM as it melts. While the field of PCM research has been well established, the use of new materials and approaches that employ the use of natural materials continues to move research forward. This review captures significant efforts and presents a thoughtful comparison of common themes across centimeter and smaller-scale PCM use. [ABSTRACT FROM AUTHOR]

In many applications, such as the miniaturization and cooling of high-power electronics in aerospace, a new thermal management solution is needed, and metal foam radiators may be a valuable solution. In this work, X-ray scanning was applied to obtain the original structure of the metal foam. The real structure calculation model of the metal foam was obtained through a series of modeling, and high-precision numerical simulation was built to study heat and mass transfer in the original structure and homogeneous substitution model for three-dimensional porous metal foam. The distribution of velocity, pressure and temperature field is investigated. The results show that the heat transfer characteristics increase and flow resistance decreases with an increase in the Reynolds number. The heat transfer performance and flow resistance increase with the decrease of porosity. The porous media homogenization model can be consistent with the original real calculation results of metal foam by using appropriate values of resistance coefficient and porosity. The variation of resistance coefficient and porosity with the working condition in the porous homogenization model is identified. [ABSTRACT FROM AUTHOR]

The paper reports the results of experimental tests and numerical simulations related to the pressure drop during two-phase air-water mixture flow through a pipe containing metal foam packing. Aluminium foam with 40 PPI open cells was used in the tests. A horizontal pipe with an internal diameter of 10 mm was used, and the foam only occupied a section of the pipe length equal to 240 mm. In the section of the pipe upwards of the foam, stratified flow pattern was generated, i.e., the most characteristic type for the gas-liquid flow. The results of the experimental research were compared with the values derived on the basis of the empirical method, which was developed for several different metal foams and two-phase systems. The values derived from measurements and calculations were subsequently applied to validate one numerical simulation method that is known to be particularly applicable for two-phase gas-liquid flow through metal foams. As a final result, the phenomena resulting from the presence of foam in the stratified flow through a gas-liquid system, the deficiencies of the methods applied in calculating pressure drops and modeling their values in accordance with the adopted numerical procedure were indicated. All research and modelling were carried out with the purpose of testing the potential of metal foam use in pipes dedicated to heat exchanger design, particularly ones intended to improve energy efficiency. [ABSTRACT FROM AUTHOR]

A two-dimensional rectangular domain is considered with a discrete arrangement at equal distances from copper metal foam in a solar air heater (SAH). The local thermal non-equilibrium model is used for the analysis of heat transfer in a single-pass rectangular channel of SAH for different mass flow rates ranging from 0.03 to 0.05 kg/s at 850 W/m2 heat flux. Three different pores per inch (PPI) and porosities of copper metal foam with three different discrete thicknesses at equal distances are studied numerically. This paper evaluates the performance of SAH with 10 PPI 0.8769 porosity, 20 PPI 0.8567 porosity, and 30 PPI 0.92 porosity at 22 mm, 44 mm, and 88 mm thicknesses. The Nusselt number for 22 mm, 44 mm, and 88 mm thicknesses is 157.64%, 183.31%, and 218.60%, respectively, higher than the empty channel. The performance factor for 22 mm thick metal foam is 5.02% and 16.61% higher than for 44 mm and 88 mm thick metal foam, respectively. Hence, it is found that metal foam can be an excellent option for heat transfer enhancement in SAH, if it is designed properly. [ABSTRACT FROM AUTHOR]

In this study, an asymmetric supercapacitor (ASSC) device is assembled by the deposition and annealing of silver-doped mixed metal oxides on reduced graphene oxide (rGO)/Ni foam and activated carbon (AC) on Ni foam as positive and negative electrodes, respectively. The best performing Ag:MnCoNiO active material is synthesized on rGO/Ni foam using chronopotentiometry combined with heat treatment. The XRD study clearly confirms the crystalline nature of the electrode with MnCo2O4 and MnNi2O4 phases. FT-IR and XPS studies revealed the formation of Ag:MnCoNiO/rGO on Ni foam. SEM images show a thin-film layer of fabricated material on the surface of rGO/Ni foam. The supercapacitor properties were tested in two- and three-electrode configurations, with cyclic voltammetry (CV), galvanostatic charge/discharge (GCD), and electrochemical impedance spectroscopy (EIS) experiments in a 6 M KOH aqueous electrolyte. In the three-electrode configuration, reversible faradic reactions can be observed in a potential range of 0.0 and +0.6 V vs. Hg/HgSO4. In the two-electrode device configuration, the system exhibits a maximum energy density of 45.5 Wh kg−1 and provides a maximum power density of 4.5 kW kg−1. The results showed that the doping of Ag in a MnCoNiO electrode shows promising properties, achieved by a very simple fabrication process. The results showcase the synergistic effects achieved by mixed multiple-component metal oxides, leading to improved supercapacitive properties. [ABSTRACT FROM AUTHOR]

A direct absorption parabolic trough solar collector (DAPTC) integrated with porous foam as a volumetric absorber has the potential to be applied as an energy conversion integrant of future renewable energy systems. The present study comprehensively analyzes a DAPTC in terms of exergy, economic, and environmental analysis for different porous configuration inserts in the absorber tube. Ten different arrangements of porous foam are examined at several HTF flow rates (40–120 L/h) and inlet temperatures (20–40 °C). The exergy efficiency, entropy generation, Bejan number, and pumping power are investigated for all cases. Obtained results indicate that fully filling the absorber tube with porous foam leads to a maximum exergy efficiency of 20.4% at the lowest inlet temperature (20 °C) and highest flow rate (120 L/h). However, the Bejan number reaches its minimum value due to the highest pumping power in this case. Consequently, all mentioned performance parameters should be considered simultaneously. Finally, the environmental and economic analyses are conducted. The results show that fully filling the absorber tube with porous foam reflects the best heat production cost, which can reduced the embodied energy, embodied water, and CO2 emission by 559.5 MJ, 1520.8 kL, and 339.62 kg, respectively, compared to the base case at the flow rate of 120 L/h. [ABSTRACT FROM AUTHOR]

To save and better deploy waste heat, the use of a mobilized heat storage system (MHSS) with phase change enhancement means is developed. In this paper, three kinds of gradient structures (positive gradient, negative gradient, and non-gradient) are designed in the MHSS system. The uniform porosity is 94% in the non-gradient structure, and the gradient porosities are 86%, 93%, and 98% in the gradient structure, respectively. Numerical models are developed to explore the contribution of the graded metal foam structure to the heat storage and release process. An economic analysis and comparison of MHSS systems with different heat transfer models are carried out. The results show that the positive gradient case can promote the thermal cycle of the melting and solidification process, while the negative gradient case inhibits the thermal cycle. The positive gradient case can reduce the melting time by 9.7% and the solidification time by 4.4%, while the negative gradient can prolong the melting time by 31.4% and the solidification time by 35.9%. Although graded metal foam increases the initial investment by 76.09%, the 1 KW·h heat cost of graded metal foam is reduced by 10.63% compared to pure phase change material (PCM). It is cost-effective in the long run of thermal cycles. [ABSTRACT FROM AUTHOR]

In this work, a commercial paraffin PCM (RT35) characterized by a change range of the solid-liquid phase transition temperature T s − l = 29 – 36 °C and the low thermal conductivity λ SL = 0.2 W/m K is experimentally tested by submitting it to thermal charging/discharging cycles. The paraffin is contained in a case with a rectangular base and heated from the top due to electrical resistance. The aim of this research is to show the benefits that a 95% porous copper metal foam (pore density P D = 20 P P I ) can bring to a PCM-based thermal storage system by simply loading it, due to the consequent increase in the effective thermal conductivity of the medium ( λ LOAD = 7.03 W/m K). The experimental results highlight the positive effects of the copper foam presence, such as the heat conduction improvement throughout the system, and a significant reduction in time for the complete melting of the PCM. In addition, the experimental data highlight that in the copper-foam-loaded PCM the maximum temperature reached during the heating process is lower than 20 K with respect to the test with pure PCM, imposing the same heat flux on the top ( P = 3.5 W/m2). [ABSTRACT FROM AUTHOR]

Metal foams have gained attention due to their heat transfer augmenting capabilities. In the literature, correlations describing relations among their morphological characteristics have successfully been established and well discussed. However, collective expressions that categorize stacked wire mesh based on their morphology and thermo-hydraulic expressions required for numerical modeling are less explored in the literature. In the present study, cross relations among the morphological characteristics of stacked wire-mesh were arrived at based on mesh-size, wire diameter and stacking type, which are essential for describing the medium and determining key input parameters required for numerical modeling. Furthermore, correlation for specific surface area, a vital parameter that plays a major role in interstitial heat transfer, is provided. With the arrived correlations, properties of stacked wire-mesh samples of orderly varied mesh-size and porosity are obtained for various stacking scenarios, and corresponding thermo-hydraulic parameters appearing in the governing equations are evaluated. A vertical channel housing the categorized wire-mesh porous media is numerically modeled to analyze thermal and flow characteristics of such a medium. The proposed correlations can be used in confidence to evaluate thermo-hydraulic parameters appearing in governing equations in order to numerically model various samples of stacked wire-mesh types of porous media in a variety of heat transfer applications. [ABSTRACT FROM AUTHOR]

Commercialization of proton exchange membrane fuel cells can only materials provided its performance is closely related to existing technologies useful in commercial application. Other critical parameters like the utilization of cheaper materials should be taken into account during the manufacturing of the cell. A key component in the cell that has direct correlation to the cell performance is the flow plate. The weight coupled with cost of the cell revolves around the flow plate used in the manufacturing of the cell. This study explores materials ideal for the manufacturing of fuel cells in order to improve the overall cell performance. The investigation highlights the critical impact of varying materials used in the manufacturing of flow plates for PEM fuel cells. Stainless steel (SS), aluminium (Al) and copper (Cu) were the materials considered. The flow plate designs considered were serpentine and open pore cellular foam channel. Machine learning using python for the validation of the results with Linear regression, Ridge regression and Polynomial regression algorithm was carried out. The performance of both flow field channels was compared using different bipolar plate materials. The results show that metal foam flow channels overall performance was better than serpentine flow channels with all the various bipolar plate material used and Al material outperformed Cu and SS material. There is a direct correlation in terms of the outcome of the study and literature based on the data generated experimentally. It can however be concluded that molecules of hydrogen are stable on aluminium plates compared to copper and stainless steel. [ABSTRACT FROM AUTHOR]

The hazards caused by gas explosion are mainly due to high temperatures and shock waves. It is of great practical significance to explore a device that can restrain these two hazards at the same time. Through the establishment of the gas explosion calculation model, a numerical analysis of the flame propagation in the three types of pipelines, including the empty pipe, the single metal foam pipe, and the high-temperature heat pipe metal foam composite structure, was carried out. The numerical results are compared with the relevant experimental results. The accuracy, rationality, and accuracy of the calculation model is verified. The research results show that that the gas explosion flame propagation develops fastest and accelerates in the empty pipe, followed by a single metal foam pipe. The gas explosion flame in the pipe with the high-temperature heat pipe metal foam composite structure develops the slowest. The composite structure composed of the high-temperature heat pipe and metal foam is an obvious choice to attenuate the temperature and overpressure of gas explosion. The high-temperature heat pipe can rapidly transmit heat in the form of phase change, and metal foam can effectively reduce the explosion pressure wave. The composite structure with the high-temperature heat pipe, and metal foam, destroys the coupling between flame and pressure wave, which acts as a barrier to explosion. It can effectively reduce the energy of flammable and explosive gas in the rear part of the pipeline and restrain the occurrence of the two explosions. The research results provide a scientific basis for the technical application of new, effective anti-explosion devices in coal mines. [ABSTRACT FROM AUTHOR]

The long standing issue of increased heat transfer, always accompanied by increased pressure drop using metal foams, is addressed in the present work. Heat transfer and pressure drop, both of various magnitudes, can be observed in respect to various flow and heat transfer influencing aspects of considered metal foams. In this regard, for the first time, orderly varying pore density (characterized by visible pores per inch, i.e., PPI) and porosity (characterized by ratio of void volume to total volume) along with varied thickness are considered to comprehensively analyze variation in the trade-off scenario between flow resistance minimization and heat transfer augmentation behavior of metal foams with the help of numerical simulations and TOPSIS (Technique for Order of Preference by Similarity to Ideal Solution) which is a multi-criteria decision-making tool to address the considered multi-objective problem. A numerical domain of vertical channel is modelled with zone of metal foam porous media at the channel center by invoking LTNE and Darcy–Forchheimer models. Metal foams of four thickness ratios are considered (1, 0.75, 0.5 and 0.25), along with varied pore density (5, 10, 15, 20 and 25 PPI), each at various porosity conditions of 0.8, 0.85, 0.9 and 0.95 porosity. Numerically obtained pressure and temperature field data are critically analyzed for various trade-off scenarios exhibited under the abovementioned variable conditions. A type of metal foam based on its morphological (pore density and porosity) and configurational (thickness) aspects, which can participate in a desired trade-off scenario between flow resistance and heat transfer, is illustrated. [ABSTRACT FROM AUTHOR]

A new geometric modeling of isotropic highly-porous cellular media, e.g., open-cell metal, ceramic, and graphite foams, is developed. The modelling is valid strictly for macroscopically two-dimensional heat transfer due to the fluid flow in highly-porous media. Unlike the current geometrical modelling of such media, the current model employs simple geometry, and is derived from equivalency conditions that are imposed on the model's geometry a priori, in order to ensure that the model produces the same pressure drop and heat transfer as the porous medium it represents. The model embodies the internal structure of the highly-porous media, e.g., metal foam, using equivalent parallel strands (EPS), which are rods arranged in a spatially periodic two-dimensional pattern. The dimensions of these strands and their arrangement are derived from equivalency conditions, ensuring that the porosity and the surface area density of the model and of the foam are indeed equal. In order to obtain the pressure drop and heat transfer results, the governing equations are solved on the geometrically-simple EPS model, instead of the complex structure of the foam. By virtue of the simple geometry of parallel strands, huge savings on computational time and cost are realized. The application of the modeling approach to metal foam is provided. It shows how an EPS model is obtained from an actual metal foam with known morphology. Predictions of the model are compared to experimental data on metal foam from the literature. The predicted local temperatures of the model are found to be in very good agreement with their experimental counterparts, with a maximum error of less than 11%. The pressure drop in the model follows the Forchheimer equation. [ABSTRACT FROM AUTHOR]

A new study investigating the cooling efficacy of air flow inside open-cell metal foam embedded in aluminum models of fuel-cell stacks is described. A model based on a commercial stack was simulated and tested experimentally. This stack has three proton exchange membrane (PEM) fuel cells, each having an active area of 100 cm2, with a total output power of 500 W. The state-of-the-art cooling of this stack employs water in serpentine flow channels. The new design of the current investigation replaces these channels with metal foam and replaces the actual fuel cells with aluminum plates. The constant heat flux on these plates is equivalent to the maximum heat dissipation of the stack. Forced air is employed as the coolant. The aluminum foam used had an open-pore size of 0.65 mm and an after-compression porosity of 60%. Local temperatures in the stack and pumping power were calculated for various air-flow velocities in the range of 0.2–1.5 m/s by numerical simulation and were determined by experiments. This range of air speed corresponds to the Reynolds number based on the hydraulic diameter in the range of 87.6–700.4. Internal and external cells of the stack were investigated. In the simulations, and the thermal energy equations were solved invoking the local thermal non-equilibrium model—a more realistic treatment for airflow in a metal foam. Good agreement between the simulation and experiment was obtained for the local temperatures. As for the pumping power predicted by simulation and obtained experimentally, there was an average difference of about 18.3%. This difference has been attributed to the poor correlation used by the CFD package (ANSYS) for pressure drop in a metal foam. This study points to the viability of employing metal foam for cooling of fuel-cell systems. [ABSTRACT FROM AUTHOR]

This paper reports the results of a study concerned with air–water and air–oil two-phase flow in channels packed with open-cell metal foams. The research was conducted in horizontal channel with an internal diameter of 0.02 m and length of 2.61 m. The analysis applied three metal foams with pore density 20, 30, and 40 PPI and porosity typical for industrial applications, changing in the range of 92–94%. The experimental data were used to develop a new method for predicting void fraction in two-phase gas–liquid flow in channels packed with metal foams. A new gas void fraction calculating method based on drift-flux model was developed. This model gives a correct representation of changes in the gas void fraction value and good prediction accuracy. The average relative error in calculating the air void fraction in two-phase flow is less than 13%, and 86% of experimental points is characterized by an error less than 20%. [ABSTRACT FROM AUTHOR]

This paper describes experimental investigations of single-phase and two-phase gas–liquid flow through channels with a diameter of 20 mm and length of 2690 mm, filled with metal foams. Three types of aluminium foams with pore densities of 20, 30 and 40 PPI and porosities ranging from 29.9% to 94.3% were used. Air, water and oil were pumped through the foams. The tests covered laminar, transitional and turbulent flow. We demonstrated that the Reynolds number, in which the hydraulic dimension should be defined based on foam porosity and pore diameter de = ϕdp/(1 − ϕ), can be used as a flow regime assessment criterion. It has been found that fluid pressure drops when flowing through metal foams significantly depends on the cell size and porosity of the foam, as well as the shape of the foam skeleton. The flow patterns had a significant influence on the pressure drop. Among other things, we observed a smaller pressure drop when plug flow changed to stratified flow. We developed a model to describe pressure drop in flow through metal foams. As per the proposed methodology, pressure drop in single-phase flow should be determined based on the friction factor, taking into account the geometrical parameters of the foams. We propose to calculate pressure drop in gas–liquid flow as the sum of pressure drops in gas and liquid pressure drop corrected by the drop amplification factor. [ABSTRACT FROM AUTHOR]

The melting flow and heat transfer of copper-oxide coconut oil in thermal energy storage filled with a nonlinear copper metal foam are addressed. The porosity of the copper foam changes linearly from bottom to top. The phase change material (PCM) is filled into the metal foam pores, which form a composite PCM. The natural convection effect is also taken into account. The effect of average porosity; porosity distribution; pore size density; the inclination angle of enclosure; and nanoparticles' concentration on the isotherms, melting maps, and the melting rate are investigated. The results show that the average porosity is the most important parameter on the melting behavior. The variation in porosity from 0.825 to 0.9 changes the melting time by about 116%. The natural convection flows are weak in the metal foam, and hence, the impact of each of the other parameters on the melting time is insignificant (less than 5%). [ABSTRACT FROM AUTHOR]

A local thermal non-equilibrium analysis of heat and fluid flow in a channel fully filled with aluminum foam is performed for three cases: (a) pore density of 5 PPI (pore per inch), (b) pore density of 40 PPI, and (c) two different layers of 5 and 40 PPI. The dimensionless forms of fully developed heat and fluid flow equations for the fluid phase and heat conduction equation for the solid phase are solved analytically. The effects of interfacial heat transfer coefficient and thermal dispersion conductivity are considered. Analytical expressions for temperature profile of solid and fluid phases, and also the channel Nusselt number ( N u H) are obtained. The obtained results are discussed in terms of the channel-based Reynolds number ( R e H) changing from 10 to 2000, and thickness ratio between the channel height and sublayers. The Nusselt number of the channel with 40 PPI is always greater than that of the 5 PPI channel. It is also greater than the channel with two-layer aluminum foams until a specific Reynolds number then the Nusselt number of the channel with two-layer aluminum foams becomes greater than the uniform channels due to the higher velocity in the outer region and considerable increase in thermal dispersion. [ABSTRACT FROM AUTHOR]

The shell-and-tube type gas-to-gas membrane humidifier used with air supply to polymer electrolyte membrane fuel cell supplies heat and vapor through a membrane and does not require an additional power source. Packing porous metal foam in the flow path of the membrane humidifier can result in higher heat and mass transfer efficiencies due to heat conduction through metal. In this study, the influence of various operating conditions and types of porous metal foams on the transport characteristics of the membrane humidifier are evaluated by simulation. The main factor causing the improvement of heat and mass transfer is the high conductivity of the porous metal foam, which is significantly correlated with the type of material used, compression ratio, and pore diameter. Additionally, the heat and mass transfer changes significantly when the flow velocity and channel size change due to the effect of the metal foam becoming more pronounced. [ABSTRACT FROM AUTHOR]

In this work, the two-dimensional laminar flow and the heat transfer in an open-ended rectangular porous channel (metal foam) including a phase change material (PCM; paraffin) under forced convection were numerically investigated. To gain further insight into the foam pore effect on charging/discharging processes, the Darcy–Brinkmann–Forchheimer (DBF) unsteady flow model and that with two temperature equations based on the local thermal non-equilibrium (LTNE) were solved at the representative elementary volume (REV) scale. The enthalpy-based thermal lattice Boltzmann method (TLBM) with triple distribution function (TDF) was employed at the REV scale to perform simulations for different porosities ( 0.7 ≤ ε ≤ 0.9 ) and pore per inch (PPI) density ( 10 ≤ P P I ≤ 60 ) at Reynolds numbers (Re) of 200 and 400 . It turned out that increasing Re with high porosity and PPI (0.9 and 60) speeds up the melting process, while, at low PPI and porosity (10 and 0.7), the complete melting time increases. In addition, during the charging process, increasing the PPI with a small porosity (0.7) weakens the forced convection in the first two-thirds of the channel. However, the increase in PPI with large porosity and high Re number limits the forced convection while improving the heat transfer. To sum up, the study findings clearly evidence the foam pore effect on the phase change process under unsteady forced convection in a PCM-saturated porous channel under local thermal non-equilibrium (LTNE). [ABSTRACT FROM AUTHOR]

In the present study, the thermal performance of an electronic equipment cooling system is investigated. The heat sink used in the current cooling system consists of a porous channel with a rectangular cross-section that is assumed to be connected directly to the hot surface of an electronic device. In this modeling, a fully developed flow assumption is used. The Darcy–Brinkman model was used to determine the fluid flow field. Since using the local thermal equilibrium (LTE) model may provide results affected by the error in metal foams, in the present research, an attempt has first been made to examine the validity range of this model. The local thermal non-equilibrium (LTNE) model taking into account the viscous dissipation effect was then used to determine the temperature field. To validate the numerical solution, the computed results were compared with other studies, and an acceptable agreement was observed. Analysis of the temperature field shows that if the fluid–solid-phase thermal conductivity ratio is 1 or the Biot number has a large value, the difference between the temperature of the solid phase and the fluid phase decreases. Moreover, the effect of important hydrodynamic parameters and the porous medium characteristics on the field of hydrodynamic, heat, and entropy generation was studied. Velocity field analysis shows that increasing the pore density and reducing the porosity cause an increase in the shear stress on the walls. By analyzing the entropy generation, it can be found that the irreversibility of heat transfer has a significant contribution to the total irreversibility, leading to a Bejan number close to 1. As a guideline for the design of a porous metal heat sink for electronic equipment, the use of porous media with low porosity reduces the total thermal resistance and improves heat transfer, reducing the total irreversibility and the Bejan number. Moreover, the increasing of pore density increases the specific porous surface; consequently, it reduces the total irreversibility and Bejan number and improves the heat transfer. [ABSTRACT FROM AUTHOR]

The presented paper deals with the metal foams, which have a wide application potential ranging from power engineering, through catalysts to impact energy absorbers. The main aim of the paper is to propose an economical non-destructive method of determining the basic characteristics and dimensions using affordable devices. The basic principle of the proposed method lies in the image capture of metal foam and their subsequent analysis in image analysis software. An important element of the work is a comparison of results obtained by the proposed method with results obtained by high-resolution X-ray microtomography. The proposed method was evaluated in terms of measurement uncertainty and propagation of error in overall results. The use of the method is limited to the metal foams, characterized by an ordered structure, which are produced mainly by the electrophoretic deposition process. Based on the descriptive statistical analysis of results, it is possible to state, that the proposed method is in great agreement with accurate, but more expensive high-resolution X-ray microtomography. [ABSTRACT FROM AUTHOR]

Portable power sources have attracted increasing interest and attention, with a focus on the reduction of the system volume. Thus, portable power sources often use polymer electrolyte fuel cell (PEFC) systems with dead-ended operation—which are simpler and more fuel-efficient than conventional PEFC systems. In these systems, the fuel may be supplied under nonhumidified conditions to minimize the balance of plant (BOP). In recent studies, metal foams have been used as flow fields to improve fuel diffusion and water management in the PEFC; the performance can be compared to that of a conventional channel. This study compared the performance and water management ability of channel and metal foam flow fields under nonhumidified conditions with dead-ended operation. The results demonstrate that the average output was similar for both flow fields. In terms of fuel efficiency, the PEFC with the metal foam could be operated for a significantly longer time without purging than that with the channel. [ABSTRACT FROM AUTHOR]

An efficient method of simulating pressure loss in a separator with metal foam is reported. In this method, a metal foam is modeled as a porous media having homogenized permeability and inertial resistance coefficients. The permeability and inertial resistance coefficients were obtained by a numerical method that was validated by experimental data from a literature. Then the pressure drop in the separator with metal foam replaced by porous media was efficiently simulated under different working conditions, and the results were analyzed. It was found that the porous media had a great effect on the pressure drop in the separator. As pores per inch (PPI) and rotating speed increase and porosity decreases, the pressure drop of the separator increases. The results indicate that replacing metal foam by porous media is effective and simulating the pressure drop is feasible and effective in a separator with metal foam. [ABSTRACT FROM AUTHOR]

In this paper, a series of experimental data about the role of the metal foam thickness on the total air flow pressure drop is presented. The tested metallic foams are based on aluminum and nickel-chromium and they are characterized by a considerable value of porosity (>0.92) and by a number of pores per linear inches (PPI) close to 10. The measures were conducted in a range of air velocity values typical for HVAC fan-coils. Under these conditions, the flow regime into the pores is highly turbulent. It was demonstrated that below a threshold value of the ratio between the thickness of the porous medium (H) and the characteristic dimension of the pores (d), the dispersion of the pressure drop values from a sample to another one can be very high. This behavior can limit the industrial use of these materials. In addition, the results presented in this paper confirm that the pressure drop data obtained under highly turbulent conditions can be conveniently used in order to determine the inertia coefficient, C, of the metal foam. [ABSTRACT FROM AUTHOR]

The energy transport inside a phase change material (PCM) based thermal energy storage system using metal foam as an enhancement technique is investigated numerically. The paraffin is used as the PCM and water as the heat transfer fluid (HTF). The transient heat transfer during the charging and discharging processes is solved, based on the volume averaged conservation equations. The flow in PCM/foam and HTF/foam composites is modelled by the Forchheimer-extended Darcy equation, while the two-temperature model is employed to account for the local thermal non-equilibrium effect between the foam matrix and fluid phase. The results show that the overall performance is greatly improved by inserting metal foam in both HTF and PCM sides. A nearly 84.9% decrease in the time needed for the total process is found compared with the case of pure PCM, and 40% compared with the case of metal foam insert only in the PCM side. Foam porosity and HTF inlet temperature greatly affect the dynamic heat storage/release process. [ABSTRACT FROM AUTHOR]

Increasingly stringent emission regulations have imposed strict requirements on the particulate matter (PM) from gasoline direct injection (GDI) engines, and the gasoline particulate filters (GPFs) are considered one of the most promising devices for meeting these requirement. To reduce the flow resistance of the GPF, a type of nested cylinder and diversion channel plug (NC-DCP) GPF is designed. It is composed of nested foam metal cylinders and annular diversion channel plugs. The pressure drop and its influencing factors were theoretically studied. The results show that the structural parameters, such as the cylindrical layer spacing and the length-to-diameter ratio, and the pressure drop have trade-off relationships. Moreover, the filtration efficiency is analyzed, and the calculation formula is summarized. The internal flow field distribution and its influencing factors are discussed based on a 2-D axisymmetric simulation. The results show that the exhaust velocity affects the flow field uniformity but does not affect the flow field structure. The pressure drop gradually decreases as the number of nested layers increases, and the positive direction is beneficial to reduce the overall pressure drop. Under different velocities, there is an optimal length-to-diameter ratio to minimize the pressure drop, and the simicircular diversion plug greatly improves the flow uniformity index for the internal flow field of the filter element. [ABSTRACT FROM AUTHOR]

Proton exchange membrane fuel cells (PEMFCs) using porous metallic foam flow-field plates have been demonstrated as an alternative to conventional rib and channel designs, showing high performance at high currents. However, the transport of liquid product water through metal foam flow-field plates in PEMFC conditions is not well understood, especially at the individual pore level. In this work, ex-situ experiments are conducted to visualise liquid water movement within a metal foam flow-field plate, considering hydrophobicity, foam pore size and air flow rate. A two-phase numerical model is then developed to further investigate the fundamental water transport behaviour in porous metal foam flow-field plates. Both the experimental and numerical work demonstrate that unlike conventional PEMFC channels, air flow rate does not have a strong influence on water removal due to the high surface tensions between the water and foam pore ligaments. A hydrophobic foam was seen to transport liquid water away from the initial injection point faster than a hydrophilic foam. In ex-situ tests, liquid water forms and maintains a random preferential pathway until the flow-field edge is reached. These results suggest that controlled foam hydrophobicity and pore size is the best way of managing water distribution in PEMFCs with porous flow-field plates. [ABSTRACT FROM AUTHOR]