The intention of this paper is to present the numerical analysis of thermal performance and exergy transfer through high porosity metal foams filled partially in a horizontal pipe. The heater is embedded on the pipe's circumference and is assigned with known heat input. To enhance heat transfer, aluminum metal foam of pore density 10 with porosity 0.95 is inserted adjacent to the pipe's inner wall. To determine the optimal thickness of metal foam for enhancing the performance thermodynamically, metal foams with five different thicknesses (10, 20, 40, 60, and 80 mm) are examined in this research for a fluid velocity ranging from 0.7 - 7 m/s under forced convection heat transfer condition. Darcy Extended Forchheimer (DEF) and local thermal non-equilibrium (LTNE) models are used for forecasting the flow features and heat transfer through the metal foams respectively. The numerical methodology implemented in this research is confirmed by comparing the present outcomes with the experimental outcomes accessible in the literature and found a fairly good agreement between them. The thermal performance is assessed in terms of heat transfer enhancement ratio and performance factor, and the thermodynamic performance is evaluated based on exergy analysis. In the exergy analysis, the parameters like mean exergy based Nusselt number (?Nu?_e), merit function (MF), and non-dimensional exergy destruction (I*) are considered for the evaluation. The result shows a better performance from partially filled metal foams than from completely filled metal foams.

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Purpose This study aims to present the numerical analysis of exergy transfer and irreversibility through the discrete filling of high-porosity aluminum metal foams inside the horizontal pipe. Design/methodology/approach In this study, the heater is embedded on the pipe’s circumference and is assigned with known heat input. To enhance the heat transfer, metal foam of 10 pores per inch with porosity 0.95 is filled into the pipe. In filling, two kinds of arrangements are made, in the first arrangement, the metal foam is filled adjacent to the inner wall of the pipe [Model (1)–(3)], and in the second arrangement, the foam is located at the center of the pipe [Models (4)–(6)]. So, six different models are examined in this research for a fluid velocity ranging from 0.7 to7 m/s under turbulent flow conditions. Darcy Extended Forchheimer is combined with local thermal non-equilibrium models for forecasting the flow and heat transfer features via metal foams. Findings The numerical methodology implemented in this study is confirmed by comparing the outcomes with the experimental outcomes accessible in the literature and found a fairly good agreement between them. The application of the second law of thermodynamics via metal foams is the novelty of current investigation. The evaluation of thermodynamic performance includes the parameters such as mean exergy-based Nusselt number (Nue), rate of irreversibility, irreversibility distribution ratio (IDR), merit function (MF) and non-dimensional exergy destruction (I*). In all the phases, Models (1)–(3) exhibit better performance than Models (4)–(6). Practical implications The present study helps to enhance the heat transfer performance with the introduction of metal foams and reveals the importance of available energy (exergy) in the system which helps in arriving at optimum design criteria for the thermal system. Originality/value The uniqueness of this study is to analyze the impact of discrete metal foam filling on exergy and irreversibility in a pipe under turbulent flow conditions.