Aerodynamic port-aligned fins to enhance thermal-hydraulic performance of jet impingement arrays

•Jet impingement arrays with aerodynamic port-aligned fins are simulated.•Port-aligned fins significantly improve heat transfer in separation zones.•Thermal-hydraulic performance maps formed for varying fin geometry.•Teardrop-shaped fins are optimal at low Re.•Continuously narrowing fins are optimal at high Re.•Fins can increase average Nu by 25% at baseline pressure drop. Jet impingement arrays with interspersed fluid extraction ports can suffer degraded heat transfer near outlets due to flow separation. This study explores the potential to integrate aerodynamic port-aligned fins on the impingement surface to maintain wall-jet attachment and increase heat transfer area. Such fins may also enhance local transport under inlet nozzles. Laminar-flow conjugate heat transfer simulations are performed for a range of Reynolds numbers and geometries to characterize this concept for slot jet impingement arrays. The simulation methodology is validated with conventional slot jet data from the literature and demonstrated to achieve mesh convergence. Overall flow characteristics are evaluated for a representative geometry, and results show a significant increase in relative average Nusselt number (Nu∗‾)and a reduction in peak temperature of the cooled surface. Conjugate heat transfer effects are evaluated, and are found to be significant for lower conductivity fin materials. Parametric studies are performed to generate performance maps for relative average Nusselt number and pressure drop as functions of Reynolds number, fin height, base width, and tip radius. Pareto curves are generated for the geometries that optimally trade heat transfer enhancement and pressure drop penalty to guide design. Teardrop shaped fins are found to be optimal for low Re, whereas continuously narrowing fins are preferable for higher Re. This jet impingement enhancement is shown to deliver up to 25% enhancement in Nu∗‾ at baseline pressure drop.