Comparative Thermal Performance of 24 Lattice Topologies Under Low-Speed Mixed Convection Using Interface Heat Transfer Metrics

This study presents a computational comparison of 24 lattice topologies over their geometrically feasible relative density ranges. Conjugate heat transfer simulations were performed in ANSYS Fluent 2024 R2 using 10 mm unit cells, inlet air at 300 K and 0.05 m/s, a constant base temperature of 312 K, and gravity acting in the negative z direction. The inlet Reynolds number was approximately 32.5. The prescribed temperature difference of 12 K gives a Grashof number of 1.68 × 103 and a Richardson number of 1.59, indicating that buoyancy and the imposed flow are both relevant. The operating condition was therefore classified as low-speed mixed convection with perpendicular forced flow and buoyancy directions. The hydrodynamic model was benchmarked against published pressure gradient data for a body-centered cubic lattice. Thermal performance was compared using interfacial area, the magnitude of the ANSYS Fluent surface heat transfer coefficient, interfacial heat transfer rate, and interfacial thermal resistance. At 10% relative density, Auxetic gave the lowest resistance, 112.34 K/W, compared with 327.51 K/W for Cube. At 70%, FBCC reached 97.56 K/W, whereas Cube reached 1028.12 K/W. Increasing relative density improved or degraded thermal performance depending on topology. The database provides comparative guidance for lattice selection and subsequent multiscale design optimization of lightweight aerospace and electronic heatsinks.