Highly accurate pressure drop prediction method for gradient lattice structures based on Darcy–Forchheimer equations

Efficient thermal utilization is crucial in energy systems. Gradient porous structures are widely used in heat transfer devices due to their enhanced heat transfer capabilities, with flow resistance characteristics representing a critical design parameter. While pressure drop prediction methodologies for homogeneous porous media are well-established, the development of rapid prediction approaches for gradient structure remains relatively unexplored. To address this research gap, the present investigation systematically evaluates pressure drop prediction methods for four distinct gradient configurations. This study encompasses the design of both continuous gradient structures (CGSs) and step gradient structures (SGSs), with two arrangement variants examined for each structural type. The research methodology combines comprehensive computational fluid dynamics simulations with full data validation. The results demonstrate that, within the parameter space investigated, the proposed prediction method achieves remarkable accuracy: for SGS configurations, the prediction error ranges from 0.16% to 1.4% along the flow direction and 0.65% to 2.4% along the heat direction. Similarly, for CGS designs, the methodology yields prediction accuracies within 1.4%–3.0% and 1.4%–4.0% for flow-directional and heat-directional analyses, respectively. These findings suggest that the developed approach provides reliable pressure drop estimation for gradient porous structures across various geometrical configurations.