Influence of Joining Techniques on the Thermal performance of Metal Foam Heat Exchanger

Metal foams are increasingly utilized in compact thermal systems due to their high surface area and excellent heat transfer capabilities. However, the method used to bond these foams to solid components may influence the overall thermal efficiency of the system. This study investigates the impact of two distinct joining techniques—Thermal Interface Materials (TIMs) and brazing—on the thermal performance of metal foam-based heat exchangers. To evaluate their effectiveness, the research focuses on key metrics such as thermal conductivity and contact resistance for both types of joints. Copper metal foam samples were integrated into heat exchanger prototypes, and a series of controlled experiments were conducted to monitor temperatures across the interfaces. The findings reveal that while both TIM and brazing/welding yield comparable overall heat transfer rates, brazing demonstrates a slight advantage due to its superior thermal conduction property. This improvement is attributed to the metallurgical bond formed during brazing, which minimizes interfacial resistance. However, brazing involves more complex fabrication processes and may alter the foam’s microstructure, potentially affecting long-term performance. In contrast, TIMs offer ease of application and flexibility during assembly, making them attractive for rapid prototyping and systems requiring frequent maintenance. The study underscores the trade-off between manufacturing simplicity and thermal performance, providing valuable insights for engineers developing next-generation heat exchangers. These findings are particularly relevant to industries such as aerospace, automotive, and electronics cooling, where optimizing thermal management is critical for system reliability and efficiency.