Aluminum Micropillar Surfaces with Hierarchical Micro- and Nanoscale Features for Enhancement of Boiling Heat Transfer Coefficient and Critical Heat Flux.

The rapid progress of electronic devices has necessitated efficient heat dissipation within boiling cooling systems, underscoring the need for improvements in boiling heat transfer coefficient (HTC) and critical heat flux (CHF). While different approaches for micropillar fabrication on copper or silicon substrates have been developed and have shown significant boiling performance improvements, such enhancement approaches on aluminum surfaces are not broadly investigated, despite their industrial applicability. This study introduces a scalable approach to engineering hierarchical micro-nano structures on aluminum surfaces, aiming to simultaneously increase HTC and CHF. One set of samples was produced using a combination of nanosecond laser texturing and chemical etching in hydrochloric acid, while another set underwent an additional laser texturing step. Three distinct micropillar patterns were tested under saturated pool boiling conditions using water at atmospheric pressure. Our findings reveal that microcavities created atop pillars successfully facilitate nucleation and micropillars representing nucleation site areas on a microscale, leading to an enhanced HTC up to 242 kW m-2 K-1. At the same time, the combination of the surrounding hydrophilic porous area enables increased wicking and pillar patterning, defining the vapor-liquid pathways on a macroscale, which leads to an increase in CHF of up to 2609 kW m-2.

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.

Heat Flux Analysis and Assessment of Drying Kinetics during Lyophilization of Fruits in a Pilot-Scale Freeze Dryer.

Vacuum freeze-drying as a process for achieving high product quality has attracted increasing attention in the last decade. Particularly in the pharmaceutical field and food processing industries, lyophilization can produce high-quality products compared to samples dried by conventional methods. Despite its benefits, lyophilization is a time-consuming and costly process that requires optimization of a number of process parameters, including shelf temperature, chamber pressure, freezing rate, and process time. This paper reports on the implementation of heat flux measurements that allow noninvasive real-time determination of the endpoint of the primary drying stage as an essential parameter for the effective optimization of the overall drying time. Quantitative analysis of the drying kinetics of five fruits (kiwifruit, avocado, Asian pear, persimmon, and passion fruit) was assessed by comparing the heat flux and temperature profiles of samples during the lyophilization process. For a 24 h lyophilization cycle, average heat fluxes in the primary drying phase ranged from 250 to 570 W/m2. A significant correlation was found between the temperature and heat flux distributions at the estimated endpoint of the sublimation process and the corresponding transition into the secondary drying stage. Furthermore, good agreement was also found for the freezing phase. The use of real-time heat flux measurements proved to be a cost-effective experimental method to better understand the process variables in order to reduce the lyophilization cycle time and overall energy consumption.

Nanosecond Laser-Textured Copper Surfaces Hydrophobized with Self-Assembled Monolayers for Enhanced Pool Boiling Heat Transfer.

Increased cooling requirements of many compact systems involving high heat fluxes demand the development of high-performance cooling techniques including immersion cooling utilizing pool boiling. This study presents the functionalization of copper surfaces to create interfaces for enhanced pool boiling heat transfer. Three types of surface structures including a crosshatch pattern, shallow channels and deep channels were developed using nanosecond laser texturing to modify the surface micro- and nanomorphology. Each type of surface structure was tested in the as-prepared superhydrophilic state and superhydrophobic state following hydrophobization, achieved through the application of a nanoscale self-assembled monolayer of a fluorinated silane. Boiling performance evaluation was conducted through three consecutive runs under saturated conditions at atmospheric pressure utilizing water as the coolant. All functionalized surfaces exhibited enhanced boiling heat transfer performance in comparison with an untreated reference. The highest critical heat flux of 1697 kW m-2 was achieved on the hydrophobized surface with shallow channels. The highest heat transfer coefficient of 291.4 kW m-2 K-1 was recorded on the hydrophobized surface with deep channels at CHF incipience, which represents a 775% enhancement over the highest values recorded on the untreated reference. Surface microstructure was identified as the key reason for enhanced heat transfer parameters. Despite large differences in surface wettability, hydrophobized surfaces exhibited comparable (or even higher) CHF values in comparison with their hydrophilic counterparts, which are traditionally considered as more favorable for achieving high CHF values. A significant reduction in bubble departure diameter was observed on the hydrophobized surface with deep channels and is attributed to effective vapor entrapment, which is pointed out as a major contributing reason behind the observed extreme boiling heat transfer performance.

Effect of Nanoparticle Size and Concentration on Pool Boiling Heat Transfer with TiO2 Nanofluids on Laser-Textured Copper Surfaces.

The enhancement of boiling heat transfer has been extensively shown to be achievable through surface texturing or fluid property modification, yet few studies have investigated the possibility of coupling both enhancement approaches. The present work focuses on exploring the possibility of concomitant enhancement of pool boiling heat transfer by using TiO2-water nanofluid in combination with laser-textured copper surfaces. Two mass concentrations of 0.001 wt.% and 0.1 wt.% are used, along with two nanoparticle sizes of 4-8 nm and 490 nm. Nanofluids are prepared using sonification and degassed distilled water, while the boiling experiments are performed at atmospheric pressure. The results demonstrate that the heat transfer coefficient (HTC) using nanofluids is deteriorated compared to using pure water on the reference and laser-textured surface. However, the critical heat flux (CHF) is significantly improved at 0.1 wt.% nanoparticle concentration. The buildup of a highly wettable TiO2 layer on the surface is identified as the main reason for the observed performance. Multiple subsequent boiling experiments using nanofluids on the same surface exhibited a notable shift in boiling curves and their instability at higher concentrations, which is attributable to growth of the nanoparticle layer on the surface. Overall, the combination of nanofluids boiling on a laser-textured surface proved to enhance the CHF after prolonged exposure to highly concentrated nanofluid, while the HTC was universally and significantly decreased in all cases.

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.

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.