Latest Advances in Metal Foam-Enhanced Heat Transfer for Phase Change Energy Storage: A Quantitative Review of Performance Boundaries and Optimization Strategies

In the context of the global transition towards energy systems with a high share of renewable energy, efficient and large-scale energy storage technologies are essential for improving the stability and flexibility of power grids. Phase change thermal energy storage has attracted considerable attention because of its high energy density and nearly isothermal heat release capability. However, its practical application remains constrained by the intrinsically low thermal conductivity of phase change materials (PCMs). For instance, 0.2–0.3 W/m·K for organic paraffins, 0.15–0.35 W/m·K for fatty acids, and 0.5–1.0 W/m·K for salt hydrates lead to slow charging and discharging rates. Incorporating metal foams into PCMs to form composite PCMs has emerged as a promising strategy, as metal foams can significantly improve effective thermal conductivity and enhance internal heat transfer. This paper systematically reviews recent advances in metal foam-enhanced phase change thermal energy storage, with particular emphasis on numerical modeling and structural optimization. First, the heat transfer enhancement mechanisms of metal foam/PCM composites are analyzed, together with the key performance indicators used to evaluate thermal storage performance. Second, material-level developments are reviewed, including pore structure parameters, interfacial engineering, and advanced fabrication methods. The review then discusses current structural design strategies, such as graded pore structures and partially filled configurations, as well as hybrid enhancement methods that combine passive and active heat transfer enhancement. Particular attention is paid to numerical modeling approaches at both pore and system scales, which are used to predict and optimize thermal behavior. In addition, optimization methods, including topology optimization, machine learning, and genetic algorithms, are examined for their potential to inversely design foam structures with tailored thermal performance. Finally, the key challenges in this field are summarized, and future research directions are proposed. These include multi-scale intelligent design, integration with complementary thermal management technologies, and the development of scalable solutions for engineering applications. This review aims to provide a systematic reference for achieving performance breakthroughs and promoting the practical deployment of phase change thermal energy storage technologies.