Experiment No.

2
Date: 30-08-2023

AN EXPERIMENTAL STUDY ON OPEN CELL METAL FOAM AS EXTENDED HEAT TRANSFER SURFACE
1) Aim:To determine the outlet temperature of air after passing through a copper foam.

2) Equipment Required:

• Cu 10 foam • Multimeter
• Temperature Sensor: Pt100 (Resistance Temperature • Blower
Detector) Specifications: 235V 750/450 W
• Differential pressure transmitter (4-20 mA) Head: 750/400 mm
• Digital flow meter I: 3.5 A/ 2.4 A
• Data Acquisition module (0-35 mA) Duty cycle: Continuous
• Current source Capacity: 1.6 2 m3/min

3) Theory:
I. UNDERSTANDING HEAT TRANSFER IN METAL FOAM
Heat transfer in metal foams is a complex and intriguing phenomenon governed by the interaction of several factors,
including the foam’s intricate structure, material properties, and the convective flow of a fluid through its porous matrix.
In this section, we delve deeper into the theoretical foundations that underpin our analysis of heat transfer in heated
metal foam.
At the heart of heat transfer in metal foam lies the fundamental process of conduction. When a heating element is
applied to the metal foam, it generates heat that is conducted through the solid structure of the foam. The foam’s unique
three-dimensional network of interconnected struts and nodes facilitates efficient heat conduction. This process can be
mathematically described by Fourier’s law of heat conduction:
dT
Q = −k × A ×
dx

Where:
• Q represents the heat transfer rate
• k is the thermal conductivity of the metal foam
• A is the cross-sectional area through which heat flows
• dT
dx is the temperature gradient along the axial direction

As the metal foam conducts heat, a continuous flow of air is introduced into the foam. This forced convection of air
plays a pivotal role in carrying away the thermal energy being conducted through the foam matrix. The convective heat
transfer process in metal foam is characterized by the convective heat transfer coefficient (h) and the Nusselt number
(Nu), which relate the convective heat transfer rate to the temperature gradient:
Q = h.A.(Tsurf ace − Tf luid )

Here, Tsurf ace is the temperature at the surface of the metal foam, and Tf luid is the temperature of the convective fluid
(air).
The placement of resistance sensors within the metal foam sample allows us to measure resistance values, which are
indicative of the temperature at their respective locations. By mapping these resistance values to temperature, we gain
insight into the temperature distribution within the foam. This distribution reveals how heat is transferred and dispersed
throughout the foam’s structure.
One of the key variables under investigation in this experiment is the airflow rate through the metal foam. Varying the
flow rate enables us to simulate different operating conditions and observe their impact on heat transfer. The PT100
sensor measures resistance changes with flow rate, which are then converted into temperature values. Analyzing these
 temperature variations provides valuable insights into the relationship between flow rate and heat transfer characteristics.
Temperature is calculated using the expression below:
Rf = Rref (1 + α × T ).......(2)
where,
Rf = Ra+Rb+Rc
3
Rref = 100ohm
α = 0.003851perC
4) Circuit Diagram:
Circuit diagram of the process is given below is given below:

Fig. 1. Circuit Diagram

R0 = Ra1 + Rb1 + Rc1

R1 = Ra2 + Rb2 + Rc2
R2 = Ra3 + Rb3 + Rc3
5) Nomenclature:
df = strut diameter
Rref = Resistance of Pt100 at 0C
α = Temperature coefficient of resistance
6) Process Diagram:
Process diagram is given below:

Fig. 2. Schematic view of the test rig for foam heat transfer and pressure drop measurement.

7) Experimental setup:

Fig. 3. (a) Experimental set up (b) Air flow control with variable openings (c) Non-insulated test section
 8) Experimental procedure:
• Experimental setup has been done as shown in figure 3 above.
• Connect both main ends of resistor combination to data acquisition system as shown in figure 2.
• Turn on the blower.
• Wait till constant temperature of 80K is achieved on both the plates.
• Take note of flow rate and percent discharge from the Rosemount’s digital flow meter.
• Take note of 3 values of voltages shown in the Microsoft Visual C++.
• Repeat the experiment by varying the flow rate inside the equipment.
9) Observations:
The convective fluid after entering the foam matrix at uniform temperature leaves with a spatial variation. It has also
been observed that the convective fluid temperature (at the exit), at any location perpendicular to the direction of the
base plate, decreases with increase in velocity of the fluid.
10) Calculations :The corresponding temperatures are calculated below.

11) Results :
The experimental results are given in the table below.

12) Conclusions:
Following major conclusions from the experiment:
(a) Metal foam attached to a plate can be treated as extended heat transfer surface (or fins) attached to primary heat
transfer area. The governing foam heat transfer equation and its solution have close resemblance with those of an ordinary
fin.
(b) The heat transfer analysis for open porous metal foams based on simple cubic model has been able to explain the
experimentally obtained temperature data with practically good accuracy