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The two-dimensional numerical simulations focused on fluid flow and heat transfer within a solar air heater (SAH) channel incorporating copper metal foam with a porosity of 90% were carried out in this study. The Local Thermal Non-equilibrium (LTNE) and Darcy-Extended Forchheimer (DEF) models were employed to predict fluid and thermal transport in the partially porous SAH channel. In the free flow zone, the turbulence model was utilized. The thermal and thermo-hydraulic performances of SAH were examined concerning several factors, including pore density ( ), Reynolds number ( ), and dimensionless foam height ( ). The results demonstrate that inserting a porous substrate into the SAH can substantially increase heat transmission. This enhancement ranges from 4.4 to 18.04 times compared to an empty duct for at . Moreover, increased porous layer height and pore density lead to a corresponding increase in pressure drop. Evaluating both the improvement in heat transmission and the associated pressure penalty, the case with , and demonstrate superior overall performance, boasting a higher Thermal Performance Factor ( ) of 2.82 when compared to an empty channel. This work presents significant findings on optimizing metal foam applications in SAH systems, offering new insights into the field.