Literature Review: Air-Cooled Heat Sink Geometries Subjected to Forced Flow

Air-cooled heat sinks remain a practical and cost-effective solution for thermal management in high power-density electronic systems. This study investigates the thermal–hydraulic performance of a plate pin-fin heat sink operating under forced convection, with emphasis on the coupled interaction between heat-transfer enhancement and pressure-drop penalty. The proposed hybrid configuration combines the low flow resistance of plate fins with the wake-induced mixing characteristics of pin-fin elements, thereby modifying boundary-layer development and flow structures within the fin channels. This review comprehensively analyzes existing experimental measurements across a range of Reynolds numbers to evaluate the average Nusselt number, thermal resistance, and friction factor. The results demonstrate that the inclusion of pin elements significantly enhances convective heat transfer through increased flow disruption and vortex formation, while incurring a moderate increase in pressure loss relative to conventional plate-fin designs. In addition, flow visualization and temperature mapping reveal improved heat transfer uniformity along the streamwise direction, particularly at intermediate Reynolds numbers where transition effects become pronounced. Empirical correlations were developed to relate the Nusselt number and friction factor to Reynolds number and key geometric ratios, providing predictive capability for thermo-hydraulic performance assessment. The findings indicate that fin-scale geometric optimization plays a dominant role in achieving improved overall performance and that the plate pin-fin configuration offers a favorable trade-off between heat-transfer augmentation and hydraulic efficiency for forced-convection electronic cooling applications.