An Overview of the Recent Advances in Pool Boiling Enhancement Materials, Structrure, and Devices

This review attempts to provide a comprehensive assessment of recent methodologies, structures, and devices for pool boiling heat transfer enhancement. Several enhancement approaches relating to the underlying fluid route and the capability to eliminate incipient boiling hysteresis, augment the nucleate boiling heat transfer coefficient, and improve the critical heat flux are assessed. Hence, this study addresses the most relevant issues related to active and passive enhancement techniques and compound enhancement schemes. Passive heat transfer enhancement techniques encompass multiscale surface modification of the heating surface, such as modification with nanoparticles, tunnels, grooves, porous coatings, and enhanced nanostructured surfaces. Also, there are already studies on the employment of a wide range of passive enhancement techniques, like displaced enhancement, swirl flow aids, and bi-thermally conductive surfaces. Moreover, the combined usage of two or more enhancement techniques, commonly known as compound enhancement approaches, is also addressed in this survey. Additionally, the present work highlights the existing scarcity of sufficiently large available databases for a given enhancement methodology regarding the influencing factors derived from the implementation of innovative thermal management systems for temperature-sensitive electronic and power devices, for instance, material, morphology, relative positioning and orientation of the boiling surface, and nucleate boiling heat transfer enhancement pattern and scale. Such scarcity means the available findings are not totally accurate and suitable for the design and implementation of new thermal management systems. The analysis of more than 100 studies in this field shows that all such improvement methodologies aim to enhance the nucleate boiling heat transfer parameters of the critical heat flux and nucleate heat transfer coefficient in pool boiling scenarios. Finally, diverse challenges and prospects for further studies are also pointed out, aimed at developing important in-depth knowledge of the underlying enhancement mechanisms of such techniques.

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.

Pool Boiling Heat Transfer Characteristics of SiO2 and BN Nanoparticles Dispersed Mono and Hybrid Nanofluids

This study reports an experimental investigation of pool boiling (PB) heat transfer performance of hybrid (two types of particles) and mono (single-particle) nanofluids consisting of Boron nitride (BN) and Silicon dioxide (SiO2) nanoparticles (NPs). While hybrid nanofluids (HNFs) were prepared in a total particle concentration of 0.05 vol.% with four different percentages of these two types of NPs (are 0.01/0.04, 0.02/ 0.03, 0.03/0.02, and 0.04/0.01 (BN vol.%/SiO2 vol.%)), two mono nanofluids (MNFs) of BN and SiO2 nanoparticles were prepared at the same total concentration of 0.05 vol.% for each NP type. Both nanofluids (NFs) were prepared in the base fluid (BF), which is the mixture of 15 vol.% of ethylene glycol (EG) and 85 vol.% of distilled water (DW). Then, the boiling heat transfer performance of these MNFs and HNFs was assessed by experimentation in a pool boiling test rig. The obtained results demonstrated good improvements in critical heat flux (CHF) and burnout heat flux (BHF) of both types of NFs. The CHF increased by up to 80% for BN-based MNF and up to 69% for HNF at 0.04 vol.% BN, which is the maximum percentage of BN into HNF, while the lowest improvement in CHF was 48% for the SiO2-based MNF compared to the BF. Similarly, the BHF was found to increase with the increasing in the loading of BN nanoparticles and a maximum enhancement of BHF of 103% for BN-based MNF was observed. These HNFs and MNFs exhibited significantly improved pool boiling heat transfer performance compared to this BF, and it became lower by increasing the percentage of SiO2 NPs in the HNFs.

Pool Boiling Heat Transfer Characteristics of New and Recycled Alumina Nanofluids

This paper reports an experimental investigation of the heat transfer features of new and recycled Alumina (Al₂O₃) nanofluids (NFs) in the pool boiling (PB) system. The mixture of ethylene glycol (EG) and distilled water (DW) is selected as the base fluid (BF), and NFs samples of two low concentrations (0.01 and 0.05 vol.%) of Al₂O₃ nanoparticles were prepared. Furthermore, the characteristics of the prepared NFs are evaluated to investigate the heat transfer performance as well as the reusability of the NFs for long-term applications and recycling consideration. Although there have been a large number of boiling studies with NFs, the current study is the first of its kind that addresses the mentioned operation conditions of recycling NF samples. The results are compared with the relevant BF in terms of properties, critical heat flux (CHF), burnout heat flux (BHF), and the convection coefficient of the Al₂O₃ NFs in the PB system. The results showed good enhancements in both CHF and BHF of these NFs yielding up to 60% and 54% for BHF at 0.05 vol.%, respectively. The reusage of the previously used (recycled) Al₂O₃ NF showed a considerable increase in heat transfer performance compared to base fluids but slightly lower than the newly prepared one. The results of the reused nanofluids demonstrate the great prospects of their recyclability in heat transfer systems and processes such as in pool boiling.

On the Critical Heat Flux Assessment of Micro- and Nanoscale Roughened Surfaces

The boiling crisis or critical heat flux (CHF) is a very critical constraint for any heat-flux-controlled boiling system. The existing methods (physical models and empirical correlations) offer a specific interpretation of the boiling phenomenon, as many of these correlations are considerably influenced by operational variables and surface morphologies. A generalized correlation is virtually unavailable. In this study, more physical mechanisms are incorporated to assess CHF of surfaces with micro- and nano-scale roughness subject to a wide range of operating conditions and working fluids. The CHF data is also correlated by using the Pearson, Kendal, and Spearman correlations to evaluate the association of various surface morphological features and thermophysical properties of the working fluid. Feature engineering is performed to better correlate the inputs with the desired output parameter. The random forest optimization (RF) is used to provide the optimal hyper-parameters to the proposed interpretable correlation and experimental data. Unlike the existing methods, the proposed method is able to incorporate more physical mechanisms and relevant parametric influences, thereby offering a more generalized and accurate prediction of CHF (R² = 0.971, mean squared error = 0.0541, and mean absolute error = 0.185).

Heat flow through a liquid-vapor interface in a nano-channel: the effect of end-grafting polymers on a wall

Heat transfer through a liquid-vapor interface is a complex phenomenon and crucially relevant in heat-removal and cryogenic applications. The physical coupling among confining walls, liquid and vapor phases is very important for controlling or improving cooling rates or condensation efficiency. Surface modification is a promising route, which has been explored to taylor the heat transfer through confined two-phase systems. We use coarse-grained molecular-dynamics simulations to study the heat transfer through a nano-confined liquid-vapor interface as a function of fluid filling. We set up a stationary heat flow through a liquid-vapor interface, stabilized with the liquid in contact with a colder wall and a vapor in contact with a hotter wall. For these physical conditions, we perform extensive simulations by progressively increasing the number of fluid particles, i.e. the channel filling, and measure the fluid distribution in the channel, density, pressure and temperature profiles We also compare the heat flux behavior between a bare-surfaces nano-channel and others where the hot surface was coated with end-grafted polymers, with different wetting affinities and bending properties. We take extreme cases of polymer properties to obtain a general picture of the polymer effect on the heat transfer, as compared with the bare surfaces. We find that walls covered by end-grafted solvophylic polymers change the heat flux by a factor of 6, as compared with bare walls, if the liquid phase is in contact with the polymers. Once the liquid wets the coated wall, the improve on heat flux is smaller and dominated by the grafting density. We also find that for a wall coated with stiff polymers, the jump in heat flux takes place at a significantly lower channel filling, when the polymers' free ends interact with the liquid surface. Interestingly, the morphology of the polymers induces a 'liquid bridge' between the liquid phase and the hot wall, through which heat is transported with high (liquid-like) thermal conductivity.

Enhancement of Boiling with Scalable Sandblasted Surfaces

Surface engineering has been leveraged by researchers to enhance boiling heat transfer performance, with benefits ranging from improved thermal management to more efficient power generation. While engineered surfaces fabricated using cleanroom processes have shown promising boiling results, scalable methods for surface engineering are still limited despite most real-world industry-scale applications involving large boiling areas. In this work, we investigate the use of sandblasting as a scalable surface engineering technique for the enhancement of pool boiling heat transfer. We vary the size of an abrasive Al₂O₃ sandblasting medium (25, 50, 100, and 150 μm) and quantify its effects on silicon surface conditions and boiling characteristics. The surface morphology and capillary wicking performance are characterized by optical profilometry and capillary rise tests, respectively. Pool boiling results and surface characterization reveal that surface roughness and volumetric wicking rate increase with the abrasive size, which results in improvements in the critical heat flux and the heat transfer coefficient of up to 192.6 and 434.3% compared to a smooth silicon surface, respectively. The significant enhancement achieved with sandblasted surfaces indicates that sandblasting is a promising option for improving boiling performance in industry-scale applications.

Hydrophilic and Hydrophobic Nanostructured Copper Surfaces for Efficient Pool Boiling Heat Transfer with Water, Water/Butanol Mixtures and Novec 649

Increasing heat dissipation requirements of small and miniature devices demands advanced cooling methods, such as application of immersion cooling via boiling heat transfer. In this study, functionalized copper surfaces for enhanced heat transfer are developed and evaluated. Samples are functionalized using a chemical oxidation treatment with subsequent hydrophobization of selected surfaces with a fluorinated silane. Pool boiling tests with water, water/1-butanol mixture with self-rewetting properties and a novel dielectric fluid with low GWP (Novec™ 649) are conducted to evaluate the boiling performance of individual surfaces. The results show that hydrophobized functionalized surfaces covered by microcavities with diameters between 40 nm and 2 µm exhibit increased heat transfer coefficient (HTC; enhancements up to 120%) and critical heat flux (CHF; enhancements up to 64%) values in comparison with the untreated reference surface, complemented by favorable fabrication repeatability. Positive surface stability is observed in contact with water, while both the self-rewetting fluids and Novec™ 649 gradually degrade the boiling performance and in some cases also the surface itself. The use of water/1-butanol mixtures in particular results in surface chemistry and morphology changes, as observed using SEM imaging and Raman spectroscopy. This seems to be neglected in the available literature and should be focused on in further studies.

Pool Boiling Performance of Multilayer Micromeshes for Commercial High-Power Cooling

With the rapid development of electronics, thermal management has become one of the most crucial issues. Intense research has focused on surface modifications used to enhance heat transfer. In this study, multilayer copper micromeshes (MCMs) are developed for commercial compact electronic cooling. Boiling heat transfer performance, including critical heat flux (CHF), heat transfer coefficients (HTCs), and the onset of nucleate boiling (ONB), are investigated. The effect of micromesh layers on the boiling performance is studied, and the bubbling characteristics are analyzed. In the study, MCM-5 shows the highest critical heat flux (CHF) of 207.5 W/cm² and an HTC of 16.5 W(cm²·K) because of its abundant micropores serving as nucleate sites, and outstanding capillary wicking capability. In addition, MCMs are compared with other surface structures in the literature and perform with high competitiveness and potential in commercial applications for high-power cooling.

Pool Boiling of Nanofluids on Biphilic Surfaces: An Experimental and Numerical Study

This study addresses the combination of customized surface modification with the use of nanofluids, to infer on its potential to enhance pool-boiling heat transfer. Hydrophilic surfaces patterned with superhydrophobic regions were developed and used as surface interfaces with different nanofluids (water with gold, silver, aluminum and alumina nanoparticles), in order to evaluate the effect of the nature and concentration of the nanoparticles in bubble dynamics and consequently in heat transfer processes. The main qualitative and quantitative analysis was based on extensive post-processing of synchronized high-speed and thermographic images. To study the nucleation of a single bubble in pool boiling condition, a numerical model was also implemented. The results show an evident benefit of using biphilic patterns with well-established distances between the superhydrophobic regions. This can be observed in the resulting plot of the dissipated heat flux for a biphilic pattern with seven superhydrophobic spots, δ = 1/d and an imposed heat flux of 2132 w/m². In this case, the dissipated heat flux is almost constant (except in the instant t* ≈ 0.9 when it reaches a peak of 2400 W/m²), whilst when using only a single superhydrophobic spot, where the heat flux dissipation reaches the maximum shortly after the detachment of the bubble, dropping continuously until a new necking phase starts. The biphilic patterns also allow a controlled bubble coalescence, which promotes fluid convection at the hydrophilic spacing between the superhydrophobic regions, which clearly contributes to cool down the surface. This effect is noticeable in the case of employing the Ag 1 wt% nanofluid, with an imposed heat flux of 2132 W/m², where the coalescence of the drops promotes a surface cooling, identified by a temperature drop of 0.7 °C in the hydrophilic areas. Those areas have an average temperature of 101.8 °C, whilst the average temperature of the superhydrophobic spots at coalescence time is of 102.9 °C. For low concentrations as the ones used in this work, the effect of the nanofluids was observed to play a minor role. This can be observed on the slight discrepancy of the heat dissipation decay that occurred in the necking stage of the bubbles for nanofluids with the same kind of nanoparticles and different concentration. For the Au 0.1 wt% nanofluid, a heat dissipation decay of 350 W/m² was reported, whilst for the Au 0.5 wt% nanofluid, the same decay was only of 280 W/m². The results of the numerical model concerning velocity fields indicated a sudden acceleration at the bubble detachment, as can be qualitatively analyzed in the thermographic images obtained in this work. Additionally, the temperature fields of the analyzed region present the same tendency as the experimental results.

Effect of IF-WS2 Nanolubricant on R134a Boiling on a Reentrant Cavity Surface

This report quantifies the influence of inorganic fullerene-like tungsten disulfide (IF-WS₂) nanoparticles on the pool-boiling performance of R134a/polyolester mixtures on a commercial (Turbo-ESP) boiling surface. Tungsten disulfide nanoparticles, of roughly 150 nm, were used at a 15% mass fraction in a base polyolester lubricant to produce the test nanolubricant. The nanolubricant was mixed with R134a at a 1% mass fraction. The study showed that the nanolubricant caused an average 37% degradation in the boiling heat flux as compared to R134a/neat-lubricant boiling on a reentrant cavity surface at the same superheat. Similarly, boiling with R134a/neat-lubricant caused, on average, a 27% degradation in the boiling heat flux as compared to pure R134a boiling and the same superheat. An analysis was presented which showed that the nanoparticles were too large and too dense to promote a boiling enhancement. In addition, the fullerene-like structure and the large size encouraged nanoparticle settling, which presumably filled cavities of the boiling surface leading to additional boiling degradations.

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.

Experimental Investigation on Pool Boiling Heat Transfer Performance Using Tungsten Oxide WO3 Nanomaterial-Based Water Nanofluids

This study aims to experimentally investigate the pool boiling heat transfer coefficient behavior using tungsten oxide-based deionized water nanofluids and comparing them to deionized water as conventional fluid. The influence of different dilute volumetric concentrations (0.005%–0.05% Vol.) and applied heat fluxes were examined to see the effect of these parameters on the pool boiling heat transfer performance using nanofluids from a typical horizontal heated copper tube at atmospheric pressure conditions. Results demonstrated that the pool boiling heat transfer coefficient (PBHTC) for both deionized water and nanofluids increased with increasing the applied heat flux. The higher PBHTC enhancement ratio was 6.7% for a volume concentration of 0.01% Vol. at a low heat flux compared to the deionized water case. Moreover, the PBHTC for nanofluids was degraded compared to the deionized water case, and the maximum reduction ratio was about 15% for a volume concentration of 0.05% Vol. relative to the baseline case. The reduction in PBHTC was attributed to the deposition of tungsten oxide nanoflakes on the heating surface during the boiling process, which led to a decrease in the density of the nucleation sites.

Pool Boiling Heat Transfer Enhanced by Fluorinated Graphene as Atomic Layered Modifiers

Graphene has been applied to thermal technology including boiling and condensation heat transfer, from which the pool boiling enhancement relies on adjusting the surface morphology and wettability that is favorable to catalyze the vaporization on the fluid/graphene interface. However, previous works using graphene or reduced graphene oxide (RGO) flake coatings, where the morphology of graphene coating is nonuniform and most of the underlying structured cavities are sealed by graphene flakes. For a long time, this hampered the unraveling of the mechanism behind the enhanced boiling performance by graphene coatings. Moreover, the previous work relied on using water-based pool boiling, which limits the scope of its practical applications since the versatile nonpolar refrigerant has been widely used in boiling heat transfer. The pool boiling was carried out on a plain copper surface to study the effect of fluorinated graphene (F-graphene) coating using nonpolar refrigerant R-141b as the working fluid along with bubble dynamic visualization. It was found that the increase of contact angle leads to more active cavities and enhances heat transfer performance up to twice as much, by applying the F-graphene coating. Moreover, the mechanism of graphene-enhanced heat transfer performance was unraveled and mainly attributed to the hydrophobic surface and effective cavity structure. This research provides a practical and reliable route for enhancing the heat transfer through F-graphene-coatings, which paves the way for potential application in graphene-based thermal technologies.

Fabrication of Micro-Patterned Surface for Pool-boiling Enhancement by Using Powder Injection Molding Process

In this study, two kinds of copper micro-patterned surfaces with different heights were fabricated by using a powder injection molding (PIM) process. The micro-pattern's size was 100 μm, and the gap size was 50 μm. The short micro-pattern's height was 100 μm, and the height of the tall one was 380 μm. A copper powder and wax-polymer-based binder system was used to fabricate the micro-patterned surfaces. The critical heat flux (CHF) and heat transfer coefficient (HTC) during pool-boiling tests were measured with the micro-patterned surfaces and a reference plain copper surface. The CHF of short and tall micro-patterned surfaces were 1434 and 1444 kW/m², respectively, and the plain copper surface's CHF was 1191 kW/m². The HTC of the plain copper surface and the PIM surface with short and tall micro-patterned surfaces were similar in value up to a heat flux 1000 kW/m². Beyond that value, the plain surface quickly reached its CHF, while the HTC of the short micro-patterned surface achieved higher values than that of the tall micro-patterned surface. At CHF, the maximum values of HTC for the short micro-pattern, tall micro-pattern, and the plain copper surface were 68, 58, and 57 kW/m² K.

Numerical Analysis of the Influence of Low Frequency Vibration on Bubble Growth

Numerical simulation of bubble growth during pool boiling under the influence of low frequency vibration was performed to understand the influence of common vibrations such as those induced by wind, highway transportation, and nearby mechanical devices on the performance of thermal systems that rely on boiling. The simulations were done for saturated R123 boiling at 277.6 K with a 15 K wall superheat. The numerical volume-of-fluid method (fixed grid) was used to define the liquid-vapor interface. The basic bubble growth characteristics including the bubble departure diameter and the bubble departure time were determined as a function of the bubble contact angle (20°-80°), the vibration displacement (10 µm-50 µm), the vibration frequency (5 Hz-25 Hz), and the initial vibration direction (positive or negative). The bubble parameters were shown to be strongly dependent on the bubble contact angle at the surface. For example, both the bubble departure diameter and the bubble departure time increased with the contact angle. At the same vibration frequency and the initial vibration direction, the bubble departure diameter and the bubble departure time both decreased with increasing vibration displacement. In addition, the vibration frequency had a greater effect on the bubble growth characteristics than did the vibration displacement. The vibration frequency effect was strongly influenced by the initial vibration direction. The pressure contour, the volume fraction of vapor phase, the temperature profile, and the velocity vector were investigated to understand these dynamic bubble behaviors. The limitation of the computational fluid dynamics approach was also described.