Thermal Entropy Generation in Magnetized Radiative Flow Through Porous Media Over a Stretching Cylinder: An RSM-Based Study

Magnetohydrodynamic (MHD) flow and heat transfer in porous media are central to many engineering applications, including heat exchangers, MHD generators, and polymer processing. This study examines the boundary layer flow and thermal behavior of an electrically conducting viscous fluid over a porous stretching tube. The model accounts for nonlinear thermal radiation, internal heat generation/absorption, and Darcy–Forchheimer drag to capture porous medium resistance. Similarity transformations reduce the governing equations to a system of coupled nonlinear ordinary differential equations, which are solved numerically using the BVP4C technique with Response Surface Methodology (RSM) and sensitivity analysis. The effects of dimensionless parameters magnetic field strength (M), Reynolds number (Re), Darcy–Forchheimer parameter (Df), Brinkman number (Br), Prandtl number (Pr), nonlinear radiation parameter (Rd), wall-to-ambient temperature ratio (rw), and heat source/sink parameter (Q) are investigated. Results show that increasing M, Df, and Q suppresses velocity and enhances temperature due to Lorentz and porous drag effects. Higher Re raises pressure but reduces near-wall velocity, while rw, Rd, and internal heating intensify thermal layers. The entropy generation analysis highlights the competing roles of viscous, magnetic, and thermal irreversibility, while the Bejan number trends distinctly indicate which mechanism dominates under different parameter conditions. The RSM findings highlight that rw and Rd consistently reduce the Nusselt number (Nu), lowering thermal efficiency. These results provide practical guidance for optimizing energy efficiency and thermal management in MHD and porous media-based systems.: