Fabrication and Characterization of an Innovative Heat Exchanger with Open Cell Aluminum Foams

:The present study deals with the design, the fabrication and the characterization of an innovative heat exchanger manufactured by using open cell aluminum foams. The cooling performances of the heat exchanger, working in low temperature difference were measured. Open cells aluminum foams, produced via polymeric foam replication method, have been assembled to manufacture the cooling elements. The wettability of the aluminum foam surface was improved through a surface treatment, in order to enhance the joining between the pipes and the metal foam. In a first phase, preliminary experimental tests on aluminum metal foam samples were used for an estimation of the overall cooling performance. The experimental test was also aimed to understand the basic mechanisms involved in the heat transfer process. In a second phase, the full heat exchanger was assembled, and an experimental setup was designed in order to determine the performance of the heat exchanger. The heat exchanger revealed its high potentiality in terms of thermal performance, showing also a remarkable behavior in terms of energy saving, assembly and endurance.