Ensemble Learning Model Analysis of Heat Transfer in Wire Coating

Abstract This study explores the wire coating process, a key technique used to enhance both the mechanical strength and environmental resistance of conductive wires by applying a molten polymer layer. To capture the complex behavior of radiative molten polymers during coating, a third‐grade fluid model is considered. The analysis considered the effects of porosity, thermal radiation, and temperature‐dependent viscosity, with viscosity characterized through the Reynolds and Vogel models. The governing nonlinear differential equations were solved using a hybrid approach that combined perturbation methods, the fourth‐order Runge–Kutta Method, and an ensemble‐learning algorithm. Graphical results demonstrated how changes in physical parameters affect both heat transfer and flow characteristics. The study found that increasing the permeability parameter leads to a clear reduction in flow velocity, attributed to higher resistance within the porous medium. Moreover, thermal radiation is shown to accelerate the coating process when porosity is present, highlighting the strong coupling between fluid properties and the porous structure.