This work studies the thermal and hydrodynamic performance of near-net square base pyramidal fins produced using the cold spray process. The manufacturing method for this new geometry of fin arrays is discussed. The fin array was tested in the inline configuration using a forced convection test apparatus. The efficiency of these surfaces is assessed by comparing the thermal conductances at the same required pumping powers. The effect of varying the array height and the fin density is evaluated and correlations are established. The performance of pyramidal pin fins is compared to that of several configurations of plain rectangular fins with similar dimensions. It is found that the pin fin arrays outperform the rectangular fins at the same fin density over the range of flow rates studied. This trend becomes more significant at increasing Reynolds number, especially in the sub-critical flow regime.
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