The challenge in thermal management is the capability to remove heat from the device while maintaining acceptable component operating temperatures. Metal foams with high porosity ε∼0.9 have in recent years emerged as a promising heat dissipation medium, due to high extended surface area densities as well as tortuous flow passages that promote the coolant flow mixing. This study focuses on investigating experimentally the thermal performance of highly porous aluminum foam heat sinks with open cells under the impingement of axial fan flows. While the porosity, foam thickness and axial fan rotation are fixed, three selected pore densities and varying impinging distance are considered. The parameters of overall thermal resistance Rθ and temperature difference ΔT are used to evaluate thermal performance of aluminum foam heat sink which is also compared with that of a conventional fin heat sink. The experimental results represent aluminum foam heat sinks can provide similar or better cooling performance with more compact (a 50% reduction in both the weight and volume) than conventional fin heat sink.

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