Metal foams and wire meshes are open cell structures with low weight and density, high permeability and high thermal conductivity which make them attractive for a wide range of industrial applications involving fluid flow and heat transfer. In this study, the effect of natural convection, radiation and heat transfer enhancement of metal foams and wire meshes of 10 and 40 PPI (pores per inch) heat exchangers were examined and compared for different heat exchanger orientation, coolant flow rate and atmosphere temperature. Thermal spray coating processes were also used in development of a new class of high temperature stainless steel heat exchangers. Stainless steel wire mesh heat exchangers were prototyped by connecting the tube to the wire mesh using wire arc thermal spray coating. Thermal spray coating provided efficient connections between the wire mesh and the tubes’ outer surface, and has potential to replace expensive brazing or other metal connection techniques.

Metal foams and wire meshes are open cell structures with low weight and density, high permeability and high thermal conductivity which make them attractive for a wide range of industrial applications involving fluid flow and heat transfer. In this study, the effect of natural convection, radiation and heat transfer enhancement of metal foams and wire meshes of 10 and 40 PPI (pores per inch) heat exchangers were examined and compared for different heat exchanger orientation, coolant flow rate and atmosphere temperature. Thermal spray coating processes were also used in development of a new class of high temperature stainless steel heat exchangers. Stainless steel wire mesh heat exchangers were prototyped by connecting the tube to the wire mesh using wire arc thermal spray coating. Thermal spray coating provided efficient connections between the wire mesh and the tubes’ outer surface, and has potential to replace expensive brazing or other metal connection techniques.