Heat transfer analysis in perforated pin fin heat sinks inspired by sterling gun barrel geometry

This study proposes and investigates a novel SGBPF (Sterling gun barrel pin fin) heat sink design, intended for high heat flux applications. This design, inspired by the Sterling gun barrel, features a solid cylindrical core and outer shell with perforations to improve the heat dissipation of the heat sink. Three types of designs (circular, Tri-Hex, and Quad Hex perforation) with various configurations were numerically studied for Re = 9973 to 19,945. The geometric parameters, such as core diameter (D c ), perforation diameter (D p ), and gap between inner core and outer shell (g), were evaluated against Nusselt number, pressure drop, friction factor, and hydrothermal performance factor (HTPF). Results showed that SGBPF with D c = 4 mm, D p = 3.25 mm, and g = 1 mm exhibited optimal thermal performance, with a peak Nusselt number of 792.08, which is approximately 44 % higher compared to a cylindrical pin fin, while achieving HTPF more than 1. Although the Tri-Hex SGBPF designs outperformed the Quad-Hex SGBPF, the circular perforation arrangement remained the most effective. Overall, the SGBPF design not only outperformed the conventional pin fin design in terms of thermohydrodynamic performance but also retains compatibility with standard machining techniques.