The present paper introduces an accurate numerical procedure to assess the internal thermal energy generation in an annular porous-finned heat sink from the sole assessment of surface temperature profile using the golden section search technique. All possible heat transfer modes and temperature dependence of all thermal parameters are accounted for in the present nonlinear model. At first, the direct problem is numerically solved using the Runge–Kutta method, whereas for predicting the prevailing heat generation within a given generalized fin domain an inverse method is used with the aid of the golden section search technique. After simplifications, the proposed scheme is credibly verified with other methodologies reported in the existing literature. Numerical predictions are performed under different levels of Gaussian noise from which accurate reconstructions are observed for measurement error up to 20%. The sensitivity study deciphers that the surface temperature field in itself is a strong function of the surface porosity, and the same is controlled through a joint trade-off among heat generation and other thermo-geometrical parameters. The present results acquired from the golden section search technique-assisted inverse method are proposed to be suitable for designing effective and robust porous fin heat sinks in order to deliver safe and enhanced heat transfer along with significant weight reduction with respect to the conventionally used systems. The present inverse estimation technique is proposed to be robust as it can be easily tailored to analyse all possible geometries manufactured from any material in a more accurate manner by taking into account all feasible heat transfer modes.
