Ultrascalable Three-Tier Hierarchical Nanoengineered Surfaces for Optimized Boiling

Bridging the Gap-Thermofluidic Designs for Precision Bioelectronics

Bioelectronics, the merging of biology and electronics, can monitor and modulate biological behaviors across length and time scales with unprecedented capability. Current bioelectronics research largely focuses on devices' mechanical properties and electronic designs. However, the thermofluidic control is often overlooked, which is noteworthy given the discipline's importance in almost all bioelectronics processes. It is believed that integrating thermofluidic designs into bioelectronics is essential to align device precision with the complexity of biofluids and biological structures. This perspective serves as a mini roadmap for researchers in both fields to introduce key principles, applications, and challenges in both bioelectronics and thermofluids domains. Important interdisciplinary opportunities for the development of future healthcare devices and precise bioelectronics will also be discussed.

Speleothem-Inspired Copper/Nickel Interfaces for Enhanced Liquid-Vapor Transport by Marangoni and Soret Effects

Geological formations have superior wickability and support the absorption of water and oils into narrow spaces of Earth's crust without external assistance. In this study, we present speleothem inspired heterogeneous porous and wicked copper (Cu)/nickel (Ni) interfaces for enhanced nucleate boiling of water/ethanol mixtures for energy-efficient separation processes. The incorporation of Ni strands within the copper particle matrix significantly enhanced heat transfer. Compared to plain copper, the Cu/Ni speleothem surfaces exhibited a 61% increase in the heat transfer coefficient for water/ethanol mixtures and a 332% increase for water, with a 58% faster onset of nucleate boiling. This enhancement was attributed to Marangoni and Soret effects at the Cu/Ni interfaces, driven by surface tension and concentration gradients. Furthermore, the synergistic wicking action of the Ni strands facilitated rewetting of the surface, replenishing liquid to the porous nucleation sites and preventing surface dry-out, thereby improving the overall heat transfer performance.

Superior Heat and Mass Transfer Performance of Bionic Wick with Finger-like Pores Inspired by the Stomatal Array of Natural Leaf

The thermal management of electronics has gained significant attention, with loop heat pipes (LHPs) emerging as an attractive solution for heat dissipation. The heat transfer performance of LHPs is influenced by the heat and mass transfer processes within the wick. However, designing the pore diameter of the wick is challenging due to the different requirements of flow resistance and capillary force. Specifically, the working fluid needs large pores to reduce resistance, while the liquid suction requires small pores to provide a large capillary force. To address this issue, we drew inspiration from the stomatal array of natural leaves used for transpiration and developed an alumina ceramic bionic wick with finger-like pores using the phase-inversion tape casting method. The finger-like pores in the wick resemble the straight hole structure of stomata, which increases the gas-liquid interface area within the wick. This design allows for timely discharge of water vapor generated by boiling, thereby reducing mass transfer resistance. Additionally, numerous micrometer-sized small pores surrounding the finger-like pores provide sufficient capillary force to replenish liquid for the gas-liquid evaporation interface. Experimental results demonstrate that the introduction of finger-like pores in the wick increases gas and water permeabilities by 2.4 and 5.2 times, respectively. Furthermore, the superior heat and mass transfer performance of the bionic wick was demonstrated with an LHP. This work effectively addresses the conflicting demands of capillary force and flow resistance, enhancing the heat transfer performance of LHPs, which holds great promise for addressing heat dissipation challenges in high power density electronic chips and has potential applications in aviation, aerospace, and microelectronics for efficient thermal management.

Effect of Surface Wettability on Nanoparticle Deposition during Pool Boiling on Laser-Textured Copper Surfaces

Prior studies have evidenced the potential for enhancing boiling heat transfer through modifications of surface or fluid properties. The deployment of nanofluids in pool boiling systems is challenging due to the deposition of nanoparticles on structured surfaces, which may result in performance deterioration. This study addresses the use of TiO2-water nanofluids (mass concentrations of 0.001 wt.% and 0.1 wt.%) in pool boiling heat transfer and concurrent mitigation of nanoparticle deposition on superhydrophobic laser-textured copper surfaces. Samples, modified through nanosecond laser texturing, were subjected to boiling in an as-prepared superhydrophilic (SHPI) state and in a superhydrophobic state (SHPO) following hydrophobization with a self-assembled monolayer of fluorinated silane. The boiling performance assessment involved five consecutive boiling curve runs under saturated conditions at atmospheric pressure. Results on superhydrophilic surfaces reveal that the use of nanofluids always led to a deterioration of the heat transfer coefficient (up to 90%) compared to pure water due to high nanoparticle deposition. The latter was largely mitigated on superhydrophobic surfaces, yet their performance was still inferior to that of the same surface in water. On the other hand, CHF values of 1209 kW m-2 and 1462 kW m-2 were recorded at 0.1 wt.% concentration on both superhydrophobic and superhydrophilic surfaces, respectively, representing a slight enhancement of 16% and 27% compared to the results obtained on their counterparts investigated in water.

Overcoming the Heat Transfer Paradox: Nano Ridges Induce "Pistol Bubbles" and Reverse the Boiling Curve

To increase the boiling heat transfer limit, we disrupted the previously nonevaporating region and increased the vaporization activity of "inert" liquid molecules by introducing nano ridges on the boiling surface. This solved the paradox of no heat transfer occurring through the thinnest liquid film in boiling bubbles; thus, the internal heat transfer limit of the bubbles was exceeded. We found that vigorous boiling occurred immediately once the nonevaporating region was activated, and the bubble frequency increased by an order of magnitude, reaching 1186 Hz, which has not been previously reported. With an increase in heat flux, the boiling curve exhibited a "return". We achieved an extremely high bubble frequency by experimentally quantifying the major influence of nonevaporating region disruption on boiling heat transfer. The mechanism behind the generation of the ultrahigh-frequency bubbles was discovered. This study also reveals a new mechanism for the reversed boiling curve.

Study on Boiling Heat Transfer Characteristics of Composite Porous Structure Fabricated by Selective Laser Melting

Surface porosity is an important means of enhancing boiling heat transfer. In this paper, two kinds of composite porous structures of surface micropore + square channel and framework micropore + square channel were prepared by selective laser melting technology using AlSi10Mg as the powder material. The effect of composites with different pore forms on boiling heat transfer was investigated in pool boiling experiments. It was found that controlling the thickness of the powder layer manufactured by selective laser melting can change the surface roughness of the sample, and the sandblasting treatment reduced the surface roughness of the samples. The average heat transfer coefficient of the rough surface composite porous structure sample was increased by 40% compared to the sandblasted sample. The micropores on the surface of the sample and inside the framework significantly enhanced the heat transfer coefficient of the composite porous structure. The presence of surface micropores increased the heat transfer area and the vaporization core density of the composite porous structure and exhibited excellent heat transfer coefficient improvement in the low heat flux region. The framework microporous composite porous structure can form effective gas-liquid diversion at high heat flux and obtain higher heat transfer performance. The large channel in the composite porous structure is the key control factor of the critical heat flux.

Tesla valves and capillary structures-activated thermal regulator

Two-phase (liquid, vapor) flow in confined spaces is fundamentally interesting and practically important in many practical applications such as thermal management, offering the potential to impart high thermal transport performance owing to high surface-to-volume ratio and latent heat released during liquid/vapor phase transition. However, the associated physical size effect, in coupling with the striking contrast in specific volume between liquid and vapor phases, also leads to the onset of unwanted vapor backflow and chaotic two-phase flow patterns, which seriously deteriorates the practical thermal transport performances. Here, we develop a thermal regulator consisting of classical Tesla valves and engineered capillary structures, which can switch its working states and boost its heat transfer coefficient and critical heat flux in its "switched-on" state. We demonstrate that the Tesla valves and the capillary structures serve to eliminate vapor backflow and promote liquid flow along the sidewalls of both Tesla valves and main channels, respectively, which synergistically enable the thermal regulator to self-adapt to varying working conditions by rectifying the chaotic two-phase flow into an ordered and directional flow. We envision that revisiting century-old design can promote the development of next generation cooling devices towards switchable and very high heat transfer performances for power electronic devices.

Advances in micro and nanoengineered surfaces for enhancing boiling and condensation heat transfer: a review

Liquid-vapor phase change phenomena such as boiling and condensation are processes widely implemented in industrial systems such as power plants, refrigeration and air conditioning systems, desalination plants, water processing installations and thermal management devices due to their enhanced heat transfer capability when compared to single-phase processes. The last decade has seen significant advances in the development and application of micro and nanostructured surfaces to enhance phase change heat transfer. Phase change heat transfer enhancement mechanisms on micro and nanostructures are significantly different from those on conventional surfaces. In this review, we provide a comprehensive summary of the effects of micro and nanostructure morphology and surface chemistry on phase change phenomena. Our review elucidates how various rational designs of micro and nanostructures can be utilized to increase heat flux and heat transfer coefficient in the case of both boiling and condensation at different environmental conditions by manipulating surface wetting and nucleation rate. We also discuss phase change heat transfer performance of liquids having higher surface tension such as water and lower surface tension liquids such as dielectric fluids, hydrocarbons and refrigerants. We discuss the effects of micro/nanostructures on boiling and condensation in both external quiescent and internal flow conditions. The review also outlines limitations of micro/nanostructures and discusses the rational development of structures to mitigate these limitations. We end the review by summarizing recent machine learning approaches for predicting heat transfer performance of micro and nanostructured surfaces in boiling and condensation applications.

A Graphene Quantum Dot Film with a Nanoengineered Crack-Like Surface via Bubble-Induced Self-Assembly for High-Power Thermal Energy Management Applications

Films with micro/nanostructures that show high wicking performance are promising in water desalination, atmospheric water harvesting, and thermal energy management systems. Here, we use a facile bubble-induced self-assembly method to directly generate films with a nanoengineered crack-like surface on the substrate during bubble growth when self-dispersible graphene quantum dot (GQD) nanofluid is used as the working medium. The crack-like micro/nanostructure, which is generated due to the thermal stress, enables the GQD film to not only have superior capillary wicking performance but also provide many additional nucleation sites. The film demonstrates enhanced phase change-based heat transfer performance, with a simultaneous enhancement of the critical heat flux and heat transfer coefficient up to 169% and 135% over a smooth substrate, respectively. Additionally, the GQD film with high stability enables a performance improvement in the concentration ratio and electrical efficiency of concentrated photovoltaics in an analytical study, which is promising for high-power thermal energy management applications.

Nature-Inspired High Temperature Scale-Resistant Slippery Lubricant-Induced Porous Surfaces (HTS-SLIPS)

Scale formation is a longstanding and unresolved problem in a number of fields, including power production, petroleum exploration, thermal desalination, and construction. Herein, a high-temperature scale-resistant slippery lubricant-induced surface (HTS-SLIPS) is developed by one-step electrodeposition and lubricant infusion. The fractal cauliflower-like morphology with lubricant oil is conducive to forming an ultralow contact angle hysteresis of ≈1°. The 10-d real-world boiling trial indicates that by replacing the uncoated surface with HTS-SLIPS, the reduction in scale mass is greater than 200% because of the low surface free energy (4.3 mJ m^-2 ) and outstanding smoothness (R_a  = 41 ± 8 nm) of HTS-SLIPS. Thanks to the scale retardation, the bubble departure frequency of HTS-SLIPS is eightfold higher than that of uncoated surfaces, signifying superior heat transfer efficiency. In these demonstrations, HTS-SLIPS coated spiral tube exhibits better flowability and lower pressure drop than the uncoated one. In addition, favorable compatibility between HTS-SLIPS and mechanical vibration is experimentally verified to strengthen the descaling of SLIPS synergistically. It is anticipated that the simple and scalable coating fabrication approach will be applicable in numerous industrial high-temperature processes where scale formation is encountered.

Computer vision-assisted investigation of boiling heat transfer on segmented nanowires with vertical wettability

The boiling efficacy is intrinsically tethered to trade-offs between the desire for bubble nucleation and necessity of vapor removal. The solution to these competing demands requires the separation of bubble activity and liquid delivery, often achieved through surface engineering. In this study, we independently engineer bubble nucleation and departure mechanisms through the design of heterogeneous and segmented nanowires with dual wettability with the aim of pushing the limit of structure-enhanced boiling heat transfer performances. The demonstration of separating liquid and vapor pathways outperforms state-of-the-art hierarchical nanowires, in particular, at low heat flux regimes while maintaining equal performances at high heat fluxes. A deep-learning based computer vision framework realized the autonomous curation and extraction of hidden big data along with digitalized bubbles. The combined efforts of materials design, deep learning techniques, and data-driven approach shed light on the mechanistic relationship between vapor/liquid pathways, bubble statistics, and phase change performance.

Three-Tier Hierarchical Structures for Extreme Pool Boiling Heat Transfer Performance

Boiling is an effective energy-transfer process with substantial utility in energy applications. Boiling performance is described mainly by the heat-transfer coefficient (HTC) and critical heat flux (CHF). Recent efforts for the simultaneous enhancement of HTC and CHF have been limited by an intrinsic trade-off between them-HTC enhancement requires high nucleation-site density, which can increase bubble coalescence resulting in limited CHF enhancement. In this work, this trade-off is overcome by designing three-tier hierarchical structures. The bubble coalescence is minimized to enhance the CHF by defining nucleation sites with microcavities interspersed within hemi-wicking structures. Meanwhile, the reduced nucleation-site density is compensated for by incorporating nanostructures that promote evaporation for HTC enhancement. The hierarchical structures demonstrate the simultaneous enhancement of HTC and CHF up to 389% and 138%, respectively, compared to a smooth surface. This extreme boiling performance can lead to significant energy savings in a variety of boiling applications.

Ultrascalable Surface Structuring Strategy of Metal Additively Manufactured Materials for Enhanced Condensation

Metal additive manufacturing (AM) enables unparalleled design freedom for the development of optimized devices in a plethora of applications. The requirement for the use of nonconventional aluminum alloys such as AlSi10Mg has made the rational micro/nanostructuring of metal AM challenging. Here, the techniques are developed and the fundamental mechanisms governing the micro/nanostructuring of AlSi10Mg, the most common metal AM material, are investigated. A surface structuring technique is rationally devised to form previously unexplored two-tier nanoscale architectures that enable remarkably low adhesion, excellent resilience to condensation flooding, and enhanced liquid-vapor phase transition. Using condensation as a demonstration framework, it is shown that the two-tier nanostructures achieve 6× higher heat transfer coefficient when compared to the best filmwise condensation. The study demonstrates that AM-enabled nanostructuring is optimal for confining droplets while reducing adhesion to facilitate droplet detachment. Extensive benchmarking with past reported data shows that the demonstrated heat transfer enhancement has not been achieved previously under high supersaturation conditions using conventional aluminum, further motivating the need for AM nanostructures. Finally, it has been demonstrated that the synergistic combination of wide AM design freedom and optimal AM nanostructuring method can provide an ultracompact condenser having excellent thermal performance and power density.

Nanoscale Thin-Film Boiling Processes on Heterogeneous Surfaces

Acquiring rapid and efficient boiling processes has been the focus of industry as they have the potential to improve the energy efficiency and reduce the carbon emissions of production processes. Here, we report nanoscale thin-film boiling on different heterogeneous surfaces. Through nonequilibrium molecular dynamics simulation, we captured the triple-phase interface details, visualized the bubble nucleation, and recorded the internal fluid flow and thermal characteristics. It is found that nanoscale thin-film boiling without the occurrence of bubble nucleation shows excellent heat and mass transfer performance, which differs from macroscale boiling. In general, rough structures advance the onset time of stable boiling and improve the efficiency. The heat transfer coefficient and heat flux on a rough hydrophilic surface respectively reach to 7.43 × 10⁴ kW/(m²·K) and 1.3 × 10⁶ kW/m² at a surface temperature of 500 K, which are 100-fold higher than those of micrometer-scale thin-film boiling. However, due to the resultant vapor film trapped between the liquid and the surface, the rough hydrophobic surface leads to heat transfer deterioration instead. It is revealed that the underlying mechanism of regulatory effects resulting from surface physicochemical properties is originated from the variation of interfacial thermal resistance. It is available to reduce the overall interfacial resistance and further improve the heat and mass transfer efficiency through increasing surface roughness, enhancing surface wettability, and increasing the area proportion of the hydrophilic region. This work provides guidelines to achieve rapid and efficient thin-liquid-film boiling and serves as a reference for the optimized design of surfaces utilized for high-heat flux removal through vaporization processes.

Coupling droplets/bubbles with a liquid film for enhancing phase-change heat transfer

Evaporation, boiling, and condensation are fundamental liquid-vapor phase-change heat transfer processes and have been utilized in many conventional and emerging energy systems. Recent advances in the manipulation of interface wetting and heterogeneous nucleation using micro/nano-structured surfaces have enabled exciting two-phase flow dynamics and heat transfer enhancement. However, independently manipulating droplets, bubbles, or liquid films through surface modification has encountered bottlenecks. In this Perspective, we discuss an emerging strategy where droplets/bubbles are coupled with a liquid film to control fluid dynamics for minimizing the thermal resistance between the liquid-vapor interface and solid substrate, thus significantly enhancing the heat transfer performance beyond the state of the art.

Liquid film-induced critical heat flux enhancement on structured surfaces

Enhancing critical heat flux (CHF) during boiling with structured surfaces has received much attention because of its important implications for two-phase flow. The role of surface structures on bubble evolution and CHF enhancement remains unclear because of the lack of direct visualization of the liquid- and solid-vapor interfaces. Here, we use high-magnification in-liquid endoscopy to directly probe bubble behavior during boiling. We report the previously unidentified coexistence of two distinct three-phase contact lines underneath growing bubbles on structured surfaces, resulting in retention of a thin liquid film within the structures between the two contact lines due to their disparate advancing velocities. This finding sheds light on a previously unidentified mechanism governing bubble evolution on structured surfaces, which has notable implications for a variety of real systems using bubble formation, such as thermal management, microfluidics, and electrochemical reactors.

Explosive Pancake Bouncing on Hot Superhydrophilic Surfaces

The rapid detachment of liquid droplets from engineered surfaces in the form of complete rebound, pancake bouncing, or trampolining has been extensively studied over the past decade and is of practical importance in many industrial processes such as self-cleaning, anti-icing, energy conversion, and so on. The spontaneous trampolining of droplets needs an additional low-pressure environment and the manifestation of pancake bouncing on superhydrophobic surfaces requires meticulous control of macrotextures and impacting velocity. In this work, we report that the rapid pancake-like levitation of impinging droplets can be achieved on superhydrophilic surfaces through the application of heating. In particular, we discovered explosive pancake bouncing on hot superhydrophilic surfaces made of hierarchically non-interconnected honeycombs, which is in striking contrast to the partial levitation of droplets on the surface consisting of interconnected microposts. This enhanced droplet bouncing phenomenon, characterized by a significant reduction in contact time and increase in the bouncing height, is ascribed to the production and spatial confinement of pressurized vapor in non-interconnected structures. The manifestation of pancake bouncing on the superhydrophilic surface rendered by a bottom-to-up boiling process may find promising applications such as the removal of trapped solid particles.

Asymmetric Bubble Formation at Rectangular Orifices

Bubble formation in liquids is frequently observed in nature and applied in various industrial processes. These include pool and flow boiling for thermal management systems, where bubbles may form asymmetrically at narrow slits and in convective flows. While previous studies have focused on symmetric bubble formation at circular orifices, the dynamics of asymmetric bubble formation remains poorly understood. Here, we experimentally investigate bubble formation at rectangular orifices and examine the effects of the orifice size and aspect ratio and the gas flow rate on the bubble size. The asymmetric bubble shape evolution at the rectangular orifice is analyzed, and we find that the size of the bubble neck is controlled either by the orifice size or by the capillary length. Based on these findings, we develop a static force balance model to predict the bubble size in the quasi-static regime, where the roles of Bond number and aspect ratio are identified. The bubble size evolution in the dynamic regime is further understood by introducing a Weber number that evaluates the effect of the virtual mass force induced by gas flow. Our study provides physical understanding of the dynamics of asymmetric bubble formation and guidance to predict the bubble size at asymmetric orifices.

Nanoparticle-Assisted Pool Boiling Heat Transfer on Micro-Pin-Fin Surfaces

Boiling heat transfer intensification is of significant relevance to energy conversion and various cooling processes. This study aimed to enhance the saturated pool boiling of FC-72 (a dielectric liquid) by surface modifications and explore mechanisms of the enhancement. Specifically, circular and square micro pin fins were fabricated on silicon surfaces by dry etching and then copper nanoparticles were deposited on the micro-pin-fin surfaces by electrostatic deposition. Experimental results indicated that compared with a smooth surface, the micro pin fins increased the heat transfer coefficient and the critical heat flux by more than 200 and 65-83%, respectively, which were further enhanced by the nanoparticles up to 24% and more than 20%, respectively. Correspondingly, the enhancement mechanism was carefully explored by high-speed bubble visualizations, surface wickability measurements, and model analysis. It was quantitatively found that small bubble departure diameters with high bubble departure frequencies promoted high heat transfer coefficients. The wickability, which characterizes the ability of a liquid to rewet a surface, played an important role in determining the critical heat flux, but further analyses indicated that evaporation beneath bubbles was also essential and competition between the wicking and the evaporation finally triggered the critical heat flux.

Transport Phenomena in Nano/Molecular Confinements

The transport of fluid and ions in nano/molecular confinements is the governing physics of a myriad of embodiments in nature and technology including human physiology, plants, energy modules, water collection and treatment systems, chemical processes, materials synthesis, and medicine. At nano/molecular scales, the confinement dimension approaches the molecular size and the transport characteristics deviates significantly from that at macro/micro scales. A thorough understanding of physics of transport at these scales and associated fluid properties is undoubtedly critical for future technologies. This compressive review provides an elaborate picture on the promising future applications of nano/molecular transport, highlights experimental and simulation metrologies to probe and comprehend this transport phenomenon, discusses the physics of fluid transport, tunable flow by orders of magnitude, and gating mechanisms at these scales, and lists the advancement in the fabrication methodologies to turn these transport concepts into reality. Properties such as chain-like liquid transport, confined gas transport, surface charge-driven ion transport, physical/chemical ion gates, and ion diodes will provide avenues to devise technologies with enhanced performance inaccessible through macro/micro systems. This review aims to provide a consolidated body of knowledge to accelerate innovation and breakthrough in the above fields.

High-Efficiency Boiling Heat Transfer Interfaces Composed of Electroplated Copper Nanocone Cores and Low-Thermal-Conductivity Nickel Nanocone Coverings

We demonstrate that copper-based super-thin high-efficiency boiling heat transfer (BHT) interfaces can be obtained via electroplating hierarchical nickel nanocone coverings on the surface of copper nanocone cores. By regulating surface morphologies, wettability, and mass and heat transfer properties of hierarchical structures, we reveal the regulation rules of their performance. Based on this, we obtain the optimized BHT interfaces with a thickness of only 6.4 μm, which shows 228% enhancement in the maximal heat transfer coefficient, 71% enhancement in the critical heat flux, and 68% decrease in the superheat for the onset of nucleate boiling, as compared to the flat copper surface. Our studies clearly indicate that, although the in situ growth of nickel nanocones can unavoidably increase the interface thermal resistance of hierarchical structures, its optimization can still enhance BHT performance. This may be ascribed to the coupling of several interface effects such as more heat transfer area, more nucleation sites, smaller bubble departure sizes, and stronger liquid supply ability caused by hierarchical structures. Our work opens up a new avenue for the development of copper-based super-thin high-efficiency BHT interfaces, which would help enhance the efficiency of energy utilization and heat dissipation of various thermal devices.

On interfacial viscosity in nanochannels

Capillary driven transport of liquids in nanoscopic channels is an omnipresent phenomenon in nature and technology including fluid flow in the human body and plants, drug delivery, nanofluidic devices, and energy/water systems. However, the kinetics of this mass transport mechanism remains in question as the well-known Lucas-Washburn (LW) model predicts significantly faster flow rates compared to the experimental observations. We here showed the role of interfacial viscosity in capillary motion slowdown in nanochannels through a combination of experimental, analytical and molecular dynamics techniques. We showed that the slower liquid flow is due to the formation of a thin liquid layer adjacent to the channel walls with a viscosity substantially greater than the bulk liquid. By incorporating the effect of the interfacial layer, we presented a theoretical model that accurately predicts the capillarity kinetics in nanochannels of different heights. Non-equilibrium molecular dynamics simulation confirmed the obtained interfacial viscosities. The viscosities of isopropanol and ethanol within the interfacial layer were 9.048 mPa s and 4.405 mPa s, respectively (i.e. 279% and 276% greater than their bulk values). We also showed that the interfacial layers are 6.4 nm- and 5.3 nm-thick for isopropanol and ethanol, respectively.

Laser-Engineered Microcavity Surfaces with a Nanoscale Superhydrophobic Coating for Extreme Boiling Performance

Functionalized interfaces enhancing phase-change processes have immense applicability in thermal management. Here, a methodology for fabrication of surfaces enabling extreme boiling heat transfer performance is demonstrated, combining direct nanosecond laser texturing and chemical vapor deposition of a hydrophobic fluorinated silane. Multiple strategies of laser texturing are explored on aluminum with subsequent nanoscale hydrophobization. Both superhydrophilic and superhydrophobic surfaces with laser-engineered microcavities exhibit significant enhancement of the pool boiling heat transfer. Surfaces with superhydrophobic microcavities allow for enhancements of a heat transfer coefficient of over 500%. Larger microcavities with a mean diameter of 4.2 μm, achieved using equidistant laser scanning separation, induce an early transition into the favorable nucleate boiling regime, while smaller microcavities with a mean diameter of 2.8 μm, achieved using variable separation, provide superior performance at high heat fluxes. The enhanced boiling performance confirms that the Wenzel wetting regime is possible during boiling on apparently superhydrophobic surfaces. A notable critical heat flux enhancement is demonstrated on superhydrophobic surfaces with an engineered microstructure showing definitively the importance and concomitant effect of both the surface wettability and topography for enhanced boiling. The fast, low-cost, and repeatable fabrication process has great potential for advanced thermal management applications.

Laser-Engineered Microcavity Surfaces with a Nanoscale Superhydrophobic Coating for Extreme Boiling Performance

Functionalized interfaces enhancing phase-change processes have immense applicability in thermal management. Here, a methodology for fabrication of surfaces enabling extreme boiling heat transfer performance is demonstrated, combining direct nanosecond laser texturing and chemical vapor deposition of a hydrophobic fluorinated silane. Multiple strategies of laser texturing are explored on aluminum with subsequent nanoscale hydrophobization. Both superhydrophilic and superhydrophobic surfaces with laser-engineered microcavities exhibit significant enhancement of the pool boiling heat transfer. Surfaces with superhydrophobic microcavities allow for enhancements of a heat transfer coefficient of over 500%. Larger microcavities with a mean diameter of 4.2 μm, achieved using equidistant laser scanning separation, induce an early transition into the favorable nucleate boiling regime, while smaller microcavities with a mean diameter of 2.8 μm, achieved using variable separation, provide superior performance at high heat fluxes. The enhanced boiling performance confirms that the Wenzel wetting regime is possible during boiling on apparently superhydrophobic surfaces. A notable critical heat flux enhancement is demonstrated on superhydrophobic surfaces with an engineered microstructure showing definitively the importance and concomitant effect of both the surface wettability and topography for enhanced boiling. The fast, low-cost, and repeatable fabrication process has great potential for advanced thermal management applications.