Study on flow and convective heat transfer of spiral flow channels in stacked porous woven structure heat sinks

To address the nonuniform temperature gradient distribution between the central and near-wall regions of stacked high-porosity metal woven mesh heat-sink pores, this study employs the finite-volume method combined with boundary-layer theory and field-synergy theory to numerically investigate the heat transfer and flow performance of aligned-style (AS) and staggered-style (SS) metal woven meshes, as well as three twist-ratio variants of twisted tape-aligned style (TTAS) and twisted tape-staggered style (TTSS) structures. Performance metrics, including the Nusselt number, friction coefficient, and thermal resistance, were evaluated. Forced-convection tests on 3D-printed TTAS and AS prototypes with a twist ratio of Y = 2.4 were conducted to validate the numerical model. Under low-Reynolds-number conditions, twisted tapes markedly increase the Nusselt number and friction factor while reducing thermal resistance; however, the relative enhancement gradually weakens as the Reynolds number increases. Twisted tapes promote radial flow and heat dissipation, thereby reducing the temperature-gradient difference between the central and near-wall regions. The preferred Y = 2.4 yields peak PEC values of 1.056 for TTAS at 2 m/s and 1.109 for TTSS at 3 m/s, confirming a net thermo-hydraulic benefit under the corresponding operating conditions. These results provide guidance for the design of novel heat-sink architectures.