Due to their high porosity, high stiffness, light weight, large surface area-to-volume ratio, and excellent thermal properties, open-cell metal foams have been applied in a wide range of sectors and industries, including the energy, transportation, aviation, biomedical, and defense industries. Understanding the flow characteristics and pressure drop of the fluid flow in open-cell metal foams is critical for applying such materials in these scenarios. However, the state-of-the-art pressure drop correlations for open-cell foams show large deviations from experimental data. In this paper, the fundamental governing equations of fluid flow through open-cell metal foams and the determination of different foam geometry structures are first presented. A variety of published models for predicting the pressure drop through open-cell metal foams are then summarized and validated against experimental data. Finally, two empirical correlations of permeability are developed and recommended based on the model of Calmidi. Moreover, Calmidi’s model is proposed to calculate the Forchheimer coefficient. These three equations together allow calculating the pressure drop through open-cell metal foam as a function of porosity and pore diameter (or strut diameter) in a wide range of porosities ε = 85.7–97.8% and pore densities of 10–100 PPI. The findings of this study greatly advance our understanding of the flow characteristics through open-cell metal foam and provide important guidance for the design of open-cell metal foam materials for different engineering applications.

Fluid mixing plays an essential role in microscale flow systems. Here, we propose an active mixing approach which enhances the mixing of viscoelastic fluid flow in a simplified pore T-junction structure. Mixing is actively controlled by modulating the driving pressure with a sinusoidal signal at the two inlets of the T-junction. The mixing effect is numerically investigated for both Newtonian and viscoelastic fluid flows under different pressure modulation conditions. The result shows that a degree of mixing as high as 0.9 is achieved in viscoelastic fluid flows through the T-junction mixer when the phase difference between the modulated pressures at the two inlets is 180°. This modulation method can also be used in other fluid mixing devices.