As a critical component in energy transfer systems, heat exchangers play a vital role in achieving energy conservation and emission reduction. Building on previous studies of the heat transfer and flow behavior of twisted hexagonal tube heat exchangers, this study proposes six novel airfoil-inspired twisted hexagonal tube configurations, including outward convex non-deviated, outward convex left/right-deviated, inward concave non-deviated, and inward concave left/right-deviated airfoil-shaped designs. Numerical simulations employing the Realizable k-ε turbulence model were performed to systematically evaluate the heat transfer performance and flow characteristics of these configurations. The optimal configuration was identified, and the effects of key geometric parameters on thermo-hydraulic performance were systematically analyzed to guide structural optimization of the proposed designs. The results indicate that, under the synergistic interaction between the airfoil orientation and the tube twisting direction, vortex structures are induced near the airfoil regions, generating strong secondary flows. These flows significantly enhance momentum exchange and mixing between the hot and cold fluids across the boundary layer, thereby improving the convective heat transfer capability of the twisted tube. Compared with the conventional, the outward convex left-deflected airfoil-shaped twisted hexagonal tube exhibits the most favorable thermo-hydraulic performance. After optimization, the average Nusselt number increases by 45.94 %, with a maximum improvement of 49.53 %, while the average friction factor rises by 61.59 %. The overall performance evaluation criterion reaches a maximum value of 1.29, which indicates an overall thermo-hydraulic performance superior to that of several enhanced tube configurations reported in the open literature, such as elliptical twisted tubes, corrugated tubes, dimpled tapered tubes, and multi-start helical corrugated tubes. This study establishes a theoretical foundation for the design and optimization of high-efficiency twisted-tube heat exchangers.
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