A thermal spray coating process was used to deposit dense 2 mm thick metal skins on the surfaces of square cross-section channels (300 mm × 20 mm × 20 mm) of nickel and copper foams with 10 and 40 PPI (pores per inch) pore densities. A heater was wrapped around the channels to apply surface heat-fluxes varying from 427 to 6846 W/m2. Compressed air was blown through the channels at flow rates of 5–80 l/min. Foam and fluid temperature distributions along the length of the channel and the pressure drop across it were measured. The foam was modeled as a porous medium and properties such as permeability K and inertial coefficient CF were determined from the experimental data. Local and average convective heat transfer coefficients were calculated from air and foam temperature measurements. Nusselt numbers were calculated and correlated in terms of the Reynolds, Prandtl, and Darcy numbers. Heat transfer to air flowing through a 10 PPI foam channel was shown to have increased nearly seven times compared to that of hollow tube with the same dimensions.

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