Abstract In the present paper a two-dimensional convective heat transfer problem in a partially filled channel with metal foam is numerically solved in steady state regime. An external thermoelectric generators (TEG) component is placed on the top surface of the channel. The numerical analyses are accomplished assuming the local thermal equilibrium (LTE) model to simulate the presence of the aluminum foam. The working fluid is exhaust gas with properties equal to the air for fixed temperature of the upper surface of the thermo-electric generator (TEG). The thermophysical properties are assumed temperature independent and the TEG component is considered as a solid with an internal energy generation. The Ansys-Fluent code is applied in order to resolve the governing equations for gas, porous media and TEG. Several mass flow rates of exhaust gas on the inlet section of the channel are considered. Different thicknesses of aluminum foam are assumed into the duct. The foam is characterized by different porosity equal to 0.90, 0.95, 0.97. Moreover, the number of pores per inch also changes and assumes the following values of 5, 20, 40. Results are showed in terms of temperature distributions, pressure drop, thermoelectric efficiency for different exhaust gas flow rates and metal foam characteristics and thicknesses. The results highlight that the use of metal foams significantly increases the heat transfer between the surface of exhaust gas tube and hot gas. Consequently, the effectiveness improves, and it increases between three-ten times with respect to the one for tube without metal foams. It is shown that the pore density does not affect the effectiveness.