Optimization of Metal Foam Heat Sink Performance: A Computational Fluid Dynamics Study

Abstract

In the era of compact and high-power electronics, effective thermal management systems are crucial. Metal foams, with their
high porosity and superior thermal conductivity, offer a promising alternative to traditional finned heat sinks. This study
presents a Computational Fluid Dynamics (CFD) analysis using ANSYS Fluent to optimize the thermal and flow performance of
metal foam-based heat sinks. The optimization focuses on key structural parameters such as porosity, pore density (PPI), foam
thickness, and base material thermal conductivity. Simulations are conducted across varying Reynolds numbers under forced
convection conditions. The study evaluates performance based on temperature distribution, pressure drop, and heat transfer
coefficient. Results show a complex interplay between geometry and performance, where increased porosity improves thermal
conductivity but raises flow resistance. An optimal configuration is proposed, balancing thermal and hydraulic performance.
This work provides a basis for designing next-generation passive cooling solutions for electronic systems.