Numerical Study on the Influence of Surface Modification Enhancing Thermal Performance and Optimization in Microchannel Heat Exchangers

Numerical investigations on the thermal performance of microchannel heat sinks featuring pin-fin surface modifications have been performed using Computational Fluid Dynamics (CFD) simulations. The simulations have been carried out to assess the flow and heat transfer behavior across 55 distinct microchannel configurations with varying pin fin heights with water as the coolant medium. The performance of pin-fin-enabled microchannels was compared against conventional flat microchannel to quantify the enhancement effects. Two fin heights (40 µm and 60 µm) were examined in laminar flow regime across Reynolds numbers ranging from 500 to 2000. Results indicate that the integration of pin fins significantly improves thermal response by amplifying heat transfer surface area and inducing localized flow disturbances. The channel configuration with 60 µm fin height demonstrated optimal performance, achieving a notable increase in the Nusselt number and overall heat transfer efficiency. These findings suggest that surface modifications through pin fins, even with water as a base fluid, can substantially enhance the thermal capability of microchannel heat exchangers and are suitable for compact, high-performance cooling applications.