Developing ANN-based metal foam pressure drop correlations to optimize IHX length in low-GWP cooling systems

Sisman S., Ipekoglu M., Parmaksizoglu I. C.

Journal of Thermal Analysis and Calorimetry, 2026 (SCI-Expanded, Scopus)

  • Publication Type: Article / Article
  • Publication Date: 2026
  • Doi Number: 10.1007/s10973-026-16294-6
  • Journal Name: Journal of Thermal Analysis and Calorimetry
  • Journal Indexes: Science Citation Index Expanded (SCI-EXPANDED), Scopus, Aerospace Database, Chemical Abstracts Core, Chimica, Compendex, Index Islamicus, INSPEC, Academic Search Ultimate (EBSCO), Engineering Source (EBSCO), Materials Science & Engineering Collection (ProQuest), Technology Collection (ProQuest)
  • Keywords: Cooling system, Internal heat exchanger, Low-GWP refrigerant, Metal foam, Pressure drop
  • Istanbul University Affiliated: Yes

Abstract

As the urgency to increase efficiency and reduce high-GWP refrigerants grows due to climate change, metal foam-enhanced solutions have become increasingly relevant. Although metal foams are widely valued for their high thermal conductivity and large surface area, their integration into cooling systems has been limited, primarily due to the associated pressure drops. In this study, metal foam-enhanced cooling cycle was modeled to evaluate low-GWP alternatives to R404A. Trained an artificial neural network (ANN) using experimental datasets and integrated its predictions into the cooling system model. The results show that by adding metal foam, the length of the internal heat exchanger can be significantly reduced and efficiency increased for the same cooling performance. This reduction also decreases the total amount of refrigerant flow rate required in the system. The effects of alternative refrigerants on the length, heat and pressure drop performance of the metal foam-enhanced internal heat exchanger are examined. The effects of alternative low-GWP refrigerants on the exchanger lengths, pressure drops, and cooling performance of internal heat exchangers with metal foam addition were investigated and the most suitable R404A alternative refrigerant was determined as R1234yf, and pressure drop correlations for metal foams was developed.