Influence of surface topography in the boiling mechanisms

The present paper addresses the qualitative and quantitative analysis of the pool boiling heat transfer over micro-structured surfaces. The surfaces are made from silicon chips, in the context of pool boiling heat transfer enhancement of immersion liquid cooling schemes for electronic components. The first part of the analysis deals with the effect of the liquid properties. Then the effect of surface micro-structuring is discussed, covering different configurations, from cavities to pillars being the latter used to infer on the potential profit of a fin-like configuration. The use of rough surfaces to enhance pool boiling mainly stands on the arguments that the surface roughness will increase the liquid–solid contact area, thus enhancing the convection heat transfer coefficient and will promote the generation of nucleation sites. However, one should not disregard bubble dynamics. Indeed, the results show a strong effect of bubble dynamics and particularly of the interaction mechanisms in the overall cooling performance of the pair liquid–surface. The inaccurate control of these mechanisms leads to the formation of large bubbles and strong vertical and horizontal coalescence effects promote the very fast formation of a vapor blanket, which causes a steep decrease of the heat transfer coefficient. This effect can be strong enough to prevail over the benefit of increasing the contact area by roughening the surface. For the micro-patterns used in the present work, the results evidence that one can reasonably determine guiding pattern characteristics to evaluate the intensity of the interaction mechanisms and take out the most of the patterning to enhance pool boiling heat transfer, when using micro-cavities. Instead, it is far more difficult to control the appearance of active nucleation sites and the optimization of the patterns allowing a reasonable control of the interaction mechanisms and in particular of horizontal coalescence, when dealing with the patterns based on micro-pillars. Hence, providing an increase of the liquid contact area by an effective increase of the roughness ratio is not enough to assure a good performance of the micro-structured surface. Despite it was not possible to clearly evidence a pin–fin effect or of an additional cooling effect due to liquid circulation between the pillars, the results show a significant increase of the heat transfer coefficient of about 10 times for water and 8 times for the dielectric fluid, in comparison to the smooth surface, when the micro-patterning based on pillars is used.     

A method of concurrent thermographic–photographic visualization of flow boiling in a minichannel

A method is developed to capture the distribution of surface temperature while simultaneously imaging the bubble motions in diabatic flow boiling in a horizontal minichannel. Liquid crystal thermography is used to obtain highly resolved surface temperature measurements on the uniformly heated upper surface of the channel. High-speed images of the flow field are acquired simultaneously and are overlaid with the thermal images. The local surface temperature and heat transfer coefficient can be analyzed with the knowledge of the nucleation site density and location, and bubble motion and size evolution. The horizontal channel is 1.2 mm high × 23 mm wide × 357 mm long, and the working fluids are Novec 649 and R-11. Optical access is through a machined glass plate which forms the bottom of the channel. The top surface is an electrically heated 76 μm-thick Hastelloy foil held in place by a water-cooled aluminum and glass frame. The heat loss resulting from this construction is computed using a conduction model in Fluent. The model is driven by temperature measurements on the foil, glass plate and aluminum frame. This model produces a corrected value for the local surface heat flux and enables the computation of the bulk fluid temperature and heat transfer coefficient along the channel. The streamwise evolution of the heat transfer coefficient for single-phase laminar flow is compared to theoretical values for a uniform-flux boundary condition. Examples of the use of the facility for visualizing subcooled two-phase flows are presented. These examples include measurements of the surface temperature distribution around active nucleation sites and the construction of boiling curves for locations along the test surface. Points on the curve can be associated with specific image sequences so that the role of mechanisms such as nucleation and the sliding of confined bubbles may be discerned.     

Artificial boiling heat transfer in the free convection to carbonic acid solution

Free convection phenomenon has been experimentally investigated around a horizontal rod heater in carbonic acid solution. Because of the tendency of the solution to desorb carbon dioxide gas when temperature is increased, bubbles appear when cylinder surface is heated. The bubbles consists mainly carbon dioxide and also a negligible amount of water vapor. The results present that dissolved carbon dioxide in water significantly enhances the heat transfer coefficient in compare to pure free convection regime. This is mainly due to the microscale mixing on the heat transfer surface, which is induced by bubble formation. In this investigation, experiments are performed at different bulk temperatures between 288 and 333 K and heat fluxes up to 400 kW m⁻² at atmospheric pressure. Bubble departure diameter, nucleation site density and heat transfer coefficient have been experimentally measured. A model has been proposed to predict the heat transfer coefficient.     

Effect of acoustic cavitation on boiling heat transfer

Boiling heat transfer on a horizontal circular copper tube in an acoustical field is investigated experimentally and the relation between the liquid cavitation, the boiling and the micro bubble radii are analyzed theoretically. The results show that cavitation bubbles have an important influence on the nucleation, growth and collapse of vapor embryo within cavities on the heat transfer surface and that the enhancement of boiling heat transfer by acoustic cavitation mainly depends on whether the vapor embryo is activated by the cavitation bubbles to initiate boiling.     

Electric field effects during nucleate boiling from an artificial nucleation site

An experimental study of saturated pool boiling from a single artificial nucleation site on a polished copper surface has been performed. Isolated bubbles grow and depart from the artificial cavity and the bubble dynamics are recorded with a high speed camera. Experimental results are obtained for bubble growth, departure and vertical rise both with and without the application of an electric field between an upper electrode and the boiling surface. As detailed in a previous paper from the same research group the high spatial and temporal resolution of the video sequences facilitated the development of a baseline experimental bubble growth law which predicts the bubble volumetric growth characteristics for a range of surface superheats at atmospheric pressure. The presence of an electric field has been found to positively augment the convective heat transfer over that of buoyant natural convection. Further to this, for high electric field strengths, the bubble shape, volumetric growth characteristics and bubble rise are different from that of the baseline cases. These results provide compelling evidence that electric fields can be implemented to alter the bubble dynamics and subsequent heat transfer rates during boiling of dielectric liquids.     

Bubble growth in saturated pool boiling in water and surfactant solution

The presence of surfactant additives in water was found to enhance the boiling heat transfer significantly. The objective of the present investigation is to compare the bubble growth in water to that of a surfactant solution with negligible environmental impact. The study was conducted at two values of heat fluxes to clarify the effect of the heat flux on the dynamics of bubble nucleation. The bubble growth under condition of pool boiling in water and non-ionic surfactant solution was studied using high speed video technique. The bubble generation was studied on a horizontal flat surface; and the natural roughness of the surface was used to produce the bubbles.     

A simultaneous PIV and heat transfer study of bubble interaction with free convection flow

Whole field velocity and point temperature and surface heat flux measurements were performed to characterise the interaction of a single rising ellipsoidal air bubble with the free convection flow from a heated flat surface immersed in water at different angles of inclination. Two thermocouples and a hot film sensor were used to characterise heat transfer from the surface, while a time-resolved digital particle image velocimetry technique was used to map the bubble induced flow in a plane parallel to the surface. Heat flux fluctuations, preceding and following the bubble passage, were shown to correlate with the variation in both local flow velocities and fluid temperatures. The largest increases in heat transfer were recorded when both flow and temperature effects combined to enhance the convective cooling simultaneously. Such conditions were shown to be most likely met when the block was inclined at 45°, thus forcing the bubble to slide closer to the heated surface and hence to the thermal boundary layer.     

Interactions between bubble formation and heating surface in nucleate boiling

The heat transfer and bubble formation is investigated in pool boiling of propane. Size distributions of active nucleation sites on single horizontal copper and steel tubes with different diameter and surface finishes have been calculated from heat transfer measurements over wide ranges of heat flux and selected pressure. The model assumptions of Luke and Gorenflo for the heat transfer near growing and departing bubbles, which were applied in the calculations, have been slightly modified and the calculated results have been compared to experimental investigations by high speed video techniques. The calculated number of active sites shows a good coincidence for the tube with smaller diameter, while the results for the tube with larger diameter describe the same relative increase of the active sites. The comparison of the cumulative size distribution of the active and potential nucleation sites demonstrates the same slope of the curve and that the critical radius of a stable bubble nuclei is smaller than the average cavity size.     

Simulation of flow boiling in micro-channels: Effects of inlet flow rate and hot-spots

This paper presents the findings of a numerical study on the flow boiling in a micro-channel heat sink. The Navier-Stokes equations, energy equation, and the continuity equation are solved in a finite-volume framework using the front-tracking method. The numerical method is validated by comparison with the experimental results for a slug bubble growth, and vertical flow boiling. The numerical method is then used to study the effect of changing the inflow mass-velocity on the heat transfer coefficient, bubble size distribution, and the bubble nucleation frequency for a constant heat flux. The mean heat transfer coefficient of all the cases is found to be nearly twice that of the single-phase heat transfer coefficient. The bubble nucleation frequency is found to increase monotonically with the inflow mass-velocity. The bubble size distribution along the channel is found to become flatter as the mass-velocity is increased. We identify three distinct phases of the bubble evolution, namely the initial rapid growth phase, the boiling dominant phase, and finally the condensation dominant phase. Subsequently, the numerical method is used to study the effect of having a hot-spot near the bubble nucleation site on the heat transfer characteristics. It is found that the bubble nucleation frequency increases and the bubbles’ maximum volume decreases as the intensity of the hot-spot is increased for a fixed inlet flow rate. It is also observed that the average heat transfer coefficient does not change significantly with changing the intensity of the hot-spot, and that the bubble size distribution along the channel becomes flatter as the intensity of the hot-spot is increased.     

Effects of bubble size on heat transfer enhancement by sub-millimeter bubbles for laminar natural convection along a vertical plate

Injection of sub-millimeter bubbles is considered a promising technique for enhancing natural convection heat transfer for liquids. So far, we have experimentally investigated heat transfer characteristics of laminar natural convection flows with sub-millimeter bubbles. However, the effects of the bubble size on the heat transfer have not yet been understood. The purpose of this study is to clarify the effects of the bubble size on the heat transfer enhancement for the laminar natural convection of water along a vertical heated plate with uniform heat flux. Temperature and velocity measurements, in which thermocouples and a particle tracking velocimetry technique are, respectively used, are conducted to investigate heat transfer and flow characteristics for different bubble sizes. Moreover, two-dimensional numerical simulations are performed to comprehensively understand the effects of bubble injection on the flow near the heated plate. The result shows that the ratio of the heat transfer coefficient with sub-millimeter-bubble injection to that without injection ranges from 1.3 to 2.2. The result also shows that for a constant bubble flow rate, the heat transfer coefficient ratio increases with a decrease in the mean bubble diameter. It is expected from our estimation based on both experimental data and simulation results that this increase results from an increase in the advection effect due to bubbles.     

Studies on heat transfer and flow characteristics in subcooled flow boiling—Part 1. Boiling characteristics

Measurement of wall temperature profile and photographic observation are performed for R-113 subcooled boiling flow in a channel with heat fluxes up to the CHF. The incipient boiling superheats measured are little affected by mass velocity and liquid subcooling. Hysteresis in boiling observed by increasing and decreasing heat flux seems to be ascribed to variation in size of active nucleation cavities on the wall. Increasing heat flux up to the CHF, the bubble density on the heated surface increases and remarkably large coalescent bubbles appear periodically near the heating section outlet.     

Transient behavior of boiling bubbles generated on the small heater of a thermal ink jet printhead

The fundamental behavior of boiling bubbles generated on a small film heater used for thermal ink jet (TIJ) printers is investigated experimentally under the condition of a single pulse heating in a pool of water. The pulse power and the pulse width are varied in wide ranges that include the printing conditions. As the pulse power is increased or the pulse width increased at a fixed high pulse power, numerous fine bubbles appear simultaneously on the heater and then coalesce into a thin vapor film to grow to a vapor bubble, before collapsing at the center of the heater. For a long pulse width sequence, the coalesced bubble repeats the growth and collapse. Bubble behavior is also studied in the same heat flux range using a platinum film heater enabling surface temperature measurement. From a comparison of the two heaters, the dominant mechanism of nucleation on the TIJ heater is believed to be spontaneous nucleation at around the heating rate for printing. The dependence of the size and lifetime of the coalesced bubble on pulse power and pulse width are examined. Based on the analytical model presented by Asai [J. Heat Transfer 113 (1991) 973], the pressure impulse arising during the rapid evaporation of the superheated liquid, presumed to dominate the subsequent growth of the coalesced bubble, is estimated from the measured size of the coalesced bubble. The relationship between the pressure impulse and the superheat energy in the liquid is discussed.     

Heat transfer and bubble formation on horizontal copper tubes with different diameters and roughness structures

Heat transfer in flooded evaporators of the refrigeration, air conditioning or process industries is mainly enhanced by modifying the surface structure of evaporator tubes in the micro and/or macro range. To quantify the effect of such modifications, however, the influence of the basic roughness structure on the heated surface has to be separated. Starting from recent publications, experimental results of heat transfer and bubble formation from horizontal copper tubes with different outer diameters (8 or 25 mm) and roughness structures to various boiling liquids are analyzed in this paper to improve our knowledge of the specific events connected with the formation of bubbles at active nucleation sites and their effect on local heat transfer. It is shown that a single, standardized roughness parameter like the (integral) mean roughness height P _a is not sufficient to explain the effect of the heating surface structure on nucleate boiling heat transfer. Instead, detailed information on characteristic roughness parameters of the heated surfaces is necessary for the analysis, making it possible to define the size and form of cavities included in the roughness structure and their positions on the surface. An analysis that aims in this direction is given in a separate contribution to this special issue by A. Luke, who prepared the surfaces and provided the basic data on the set of standardized roughness parameters, the probability distributions of which are used in this paper.     

Preparation and analysis of different roughness structures for evaporator tubes

The processes of the phase change in boiling occur at the solid–liquid interface by heat transfer from a solid heating surface to the boiling liquid. The characteristic features of the heating surfaces are therefore of great interest to optimize the design of evaporators. The microstructure with all its peaks and cavities influences directly the wetting and rewetting conditions of the heated surface by the boiling liquid and hence bubble formation and heat transfer. The roughness structures of different evaporator copper tubes with 8 or 25 mm diameter are characterized quantitatively with regard to the cavities offered to nucleation. The surfaces of the heating elements are sandblasted by different means resulting in a stochastic microstructure. The surfaces are investigated by a three-dimensional contactless roughness measurement technique combining the stylus technique with the near field acoustic microscopy. The method opens the possibility to obtain results according to standard for practical applications and additionally delivers detailed information about the three-dimensional shape of each cavity within the surface investigated. The analysis of the microstructure implies the total number of cavities, their local and size distribution calculated by the method of the envelope area. The results of the surface analysis are linked to those of heat transfer and bubble formation discussed in a contribution by Kotthoff and Gorenflo.     

Explosive boiling of a liquid droplet

A mathematical model describing growth of an internal vapor bubble produced by homogeneous nucleation within a liquid droplet during explosive boiling is presented. Existing experimental results for explosive boiling of superheated droplets confirm the predictions of the model. The difference between the present model and the classical theories of bubble growth is discussed.     

Simulation of void fraction profile evolution in subcooled nucleate boiling flow in a vertical annulus using a bubble-tracking approach

A three-dimensional bubble-tracking model of subcooled nucleate boiling flow in a vertical channel at low-pressure conditions is proposed with specific application to the case of boiling in an annulus with a central heating rod. Vapour is distributed in the liquid in the form of individually tracked bubbles. The overall behaviour of the liquid–vapour system results from motion, interaction, coalescence and boiling mechanisms prescribed mostly at the level of bubbles. Bubbles are nucleated at nucleation sites randomly distributed over the heated surface. After nucleation, bubbles slide on the heated wall, detach and then migrate into the lower-temperature region away from the heated surface, where they condense. The proposed model was applied to experiments on subcooled boiling from Purdue University (USA). Experimental and calculated void fraction radial profiles at different axial locations are compared.     

Studies on heat transfer and flow characteristics in subcooled flow boiling—Part 2. Flow characteristics

Distributions of fluid temperature and its fluctuation are measured across a R-113 subcooled boiling flow channel with heat fluxes up to the CHF. A microthermocouple probe associated with an electric compensation circuit for the time constant is used for this purpose. Applying statistical treatments to the recorded temperature fluctuation, the heat transfer process in the flow and the characteristics of the bubbles flowing close to the heated surface are investigated. For high heat fluxes nearby the CHF, some bubbles adjacent to the heated surface show a clear trend to coalesce to large volume bubbles with relatively long passing periods, suggesting a mechanism of departure from nucleate boiling by periodical wall temperature rise due to momentary liquid film dryout underneath the large bubbles.     

A multiphase DNS approach for handling solid particles motion with heat transfer

In the current work we propose a multiphase DNS method capable of resolving the motion of solid particles coupled with heat transfer effects. The method is based on solving a shared set of momentum and energy balance equations for the carrier phase and the particulate phase. Individual particles are tracked using a number of volume fraction advection equations. The proposed method is in very good agreement with the available data in the literature for the following cases: isothermal particle motion (in the presence of walls and other particles), natural convection around a stationary particle and solid particles motion accompanied with heat transfer effects. In addition, we show that the method is inherently capable of handling deformable particles (i.e. droplets and bubbles) co-existing with solid particles. The method is thus well suited to deal with challenging multiphase systems, such as diesel spray combustion with soot formation, spray drying with particle nucleation, and biological treatment of waste water.     

Flow boiling behaviors in hydrophilic and hydrophobic microchannels

Surface wettability is a critical parameter in small scale phenomena, especially two-phase flow, since the surface force becomes dominant as size decreases. In present study, experiments of water flow boiling in hydrophilic and hydrophobic rectangular microchannels were conducted to investigate the wettability effect on flow boiling in rectangular microchannels. The rectangular microchannels were fabricated with a photosensitive glass to visualize flow pattern. The hydrophilic bare photosensitive glass microchannel was chemically treated to obtain a hydrophobic microchannel. And, visualization of flow patterns was carried out. And boiling heat transfer and two-phase pressure drop was analyzed with visualization results. The boiling heat transfer coefficient in the hydrophobic rectangular microchannel was higher than that in the hydrophilic rectangular microchannel, which was highly related with nucleation site density and liquid film motion. And the pressure drop in the hydrophobic rectangular microchannel was higher than that in the hydrophilic rectangular microchannel, which was highly related with unstable motions of bubble and liquid film. Finally, we find out the wettability is important parameter on the flow pattern, which were highly related with two-phase heat and mass transfer.