Investigation on the performance of a novel heat transfer structure based on a new twisted airfoil fin array

• A novel heat transfer structure based on a new twisted airfoil fin array is proposed. • A fluid dynamics-based twisted airfoil fin is proposed. • The critical design parameters of the twisted airfoil fin are elaborately designed. • The fins exhibit unique features of enhanced heat transfer and comprehensive performance. • The Nusselt number of the heat exchanger is improved up to 52%, and the performance evaluation criteria is increased up to 16%. Printed circuit heat exchanger (PCHE) is a type of micro-channel heat exchanger with high performance, which has a broad application in microelectronics, solar energy, and aerospace. Airfoil fins are widely recognized due to their exceptional thermo-hydraulic performance, but there are few studies on their shape adjustment in three dimensions. In this study, a novel twisted airfoil fin was proposed and applied to the heat exchanger. The heat transfer and flow resistance of the twisted airfoil fin PCHE with the traditional PCHE are compared using the numerical simulation method, and the influence of the twist angle, fin spacing, and arrangement is investigated. The results show that the new fins have excellent flow and heat transfer performance. Under the multiple Re number conditions, the Nu number is improved up to 52%, and the performance evaluation criteria is increased up to 16%. Also, increasing the twist angle of the fins, decreasing the fin spacing, and staggering the fins according to diverse twist directions can improve the performance of the heat exchanger.