In recent years, heat exchangers have become essential for controlling heat transfer in industrial applications. Heat transfer augmentation of heat exchangers improves overall system performance. Twisted tape inserts are predominantly used for heat transfer augmentation through heat exchangers. This research investigates and compares the performance of steel and aluminum twisted tape inserts separately under uniform heat flux conditions using copper tubes. The twisted tapes, with their swirls along the length, act as segments for the flow of fluids in a swirling motion. Experiments were performed for both steel and aluminum twisted tapes at pitch ratios of 4, 4.5, and 5, incorporating a geometrical U-cut modification on the swirls to evaluate its effect on performance. The impact of the U cut on the rate of heat transmission was analyzed by comparing it with plain twisted tape. When the flow is considered completely turbulent, the Reynolds number lies between 15000 and 45000. Results show that a U-cut twist of aluminum with a pitch ratio of 4 performed best, with excellent heat resistance and a thermal performance factor of 1.6. In contrast to ordinary tubes, tubes of U-cut with twisted inserts showed an average 40–50% increase in heat flow. The observed 46% improvement in heat transfer and a thermal performance factor of 1.6 indicate that aluminum U-cut twisted tape inserts can be applied in industrial heat exchangers for power generation, chemical processing, HVAC systems, and refrigeration to achieve higher thermal efficiency and reduce energy consumption.