Influence of the aspect ratio on boiling flows in rectangular mini-channels

This article presents experiments conducted with two single rectangular mini-channels of same hydraulic diameter (1.4 mm) and different aspect ratios for conditions of horizontal boiling flow. The Forane® 365 HX used was subcooled (ΔT_sub = 15 °C) for all the boiling curves presented in the paper. Local heat transfer coefficients were measured for heat flux ranging from 25 to 62 kW m⁻² and mass flux from 200 kg m⁻² s⁻¹ to 400 kg m⁻² s⁻¹. The boiling flows were observed with two different cameras (depending on the flow velocity) through a visualization window. The flow patterns in the two channels were compared for similar conditions. The results show that the boiling heat transfer coefficient and the pressure drop values are different for the two single mini-channels. For low heat flux condition, the channel with lowest aspect ratio (H/W = 0.143) has a higher heat transfer coefficient. On the other hand, for high heat flux condition, the opposite situation occurs, namely the heat transfer coefficient becomes higher for the channel with highest aspect ratio (H/W = 0.43). This is probably due to the earlier onset of dryout in the channel with lowest aspect ratio. For the two cases of heating, the pressure drop for the two-phase flow remains lower for the channel with lowest aspect ratio. These results show that the aspect ratio plays a substantial role for boiling flows in rectangular channels. As for single-phase flows, the heat transfer characteristics are significantly influenced (even though the hydraulic diameter remains the same) by this parameter.     

Flow regime development analysis in adiabatic upward two-phase flow in a vertical annulus

In this work radial and axial flow regime development in adiabatic upward air-water two-phase flow in a vertical annulus has been investigated. Local flow regimes have been identified using conductivity probes and neural networks techniques. The inner and outer diameters of the annulus are 19.1 mm and 38.1 mm, respectively. The equivalent hydraulic diameter of the flow channel, D_H, is 19.0 mm and the total length is 4.37 m. The flow regime map includes 1080 local flow regimes identifications in 72 flow conditions within a range of 0.01 m/s < 〈j_g〉 < 30 m/s and 0.2 m/s < 〈j_f〉 < 3.5 m/s where 〈j_g〉 and 〈j_f〉 are, respectively, superficial gas and liquid velocities. The local flow regime has been classified into four categories: bubbly, cap-slug, churn-turbulent and annular flows. In order to study the radial and axial development of flow regime the measurements have been performed at five radial locations. The three axial positions correspond to z/D_H = 52, 149 and 230, where z represents the axial position. The flow regime indicator has been chosen as some statistical parameters of local bubble chord length distributions and self-organized neural networks have been used as mapping system. This information has been also used to compare the results given by the existing flow regime transition models. The local flow regime is characterized basically by the void fraction and bubble chord length. The radial development of flow regime shows partial and complete local flow regime combinations. The radial development is controlled by axial location and superficial liquid velocity. The radial flow regime transition is always initiated in the center of the flow channel and it is propagated towards the channel boundaries. The axial development of flow regime is observed in all the flow maps and it is governed by superficial liquid velocity and radial location. The prediction results of the models are compared for each flow regime transition.     

Effect of surfactant concentration on saturated flow boiling in vertical narrow annular channels

Saturated flow boiling of environmentally acceptable nonionic surfactant solutions of Alkyl (8–16) was compared to that of pure water. The concentration of surfactant solutions was in the range of 100–1000 ppm. The liquid flowed in an annular gap of 2.5 and 4.4 mm between two vertical tubes. The heat was transferred from the inner heated tube to two-phase flow in the range of mass flux from 5 to 18 kg/m² s and heat flux from 40 to 200 kW/m². Boiling curves of water were found to be heat flux and channel gap size dependent but essentially mass flux independent. An addition of surfactant to the water produced a large number of bubbles of small diameter, which, at high heat fluxes, tend to cover the entire heater surface with a vapor blanket. It was found that the heat transfer increased at low values of relative surfactant concentration C/C₀, reaches a maximum close to the value of C/C₀ = 1 (where C₀ = 300 ppm is the critical micelle concentration) and decreased with further increase in the amount of additive. The dependence of the maximal values of the relative heat transfer enhancement, obtained at the value of relative concentration of C/C₀ = 1, on the boiling number Bo may be presented as single curve for both gap sizes and the whole range of considered concentrations.     

Measurement of liquid film thickness in a micro parallel channel with interferometer and laser focus displacement meter

In the present study, liquid film thicknesses in parallel channels with heights of H = 0.1, 0.3 and 0.5 mm are measured with two different optical methods, i.e., interferometer and laser focus displacement meter. Ethanol is used as a working fluid. Liquid film thicknesses obtained from two optical methods agree very well. At low capillary numbers, dimensionless liquid film thickness is in accordance with Taylor’s law. However, as capillary number increases, dimensionless liquid film thickness becomes larger than Taylor’s law for larger channel heights. It is attributed to the dominant inertial effect at high capillary numbers. Using channel height H for dimensionless liquid film thickness δ₀/H and hydraulic diameter D_h = 2H as the characteristic length for Reynolds and Weber numbers, liquid film thickness in a parallel channel can be predicted well by the circular tube correlation previously proposed by the authors. This is because curvature differences between bubble nose and flat film region are identical in circular tubes and parallel channels.     

Subcooled flow boiling of R-134a in vertical channels of small diameter

Subcooled flow boiling heat transfer for refrigerant R-134a in vertical cylindrical tubes with 0.83, 1.22 and 1.70 mm internal diameter was experimentally investigated. The effects of the heat flux, q″ = 1–26 kW/m², mass flux, G = 300–700 kg/m² s, inlet subcooling, ΔT_sub,i = 5–15 °C, system pressure, P = 7.70–10.17 bar, and channel diameter, D, on the subcooled boiling heat transfer were explored in detail. The results are presented in the form of boiling curves and heat transfer coefficients. The boiling curves evidenced the existence of hysteresis when increasing the heat flux until the onset of nucleate boiling, ONB. The wall superheat at ONB was found to be essentially higher than that predicted with correlations for larger tubes. An increase of the mass flux leads, for early subcooled boiling, to an increase in the heat transfer coefficient. However, for fully developed subcooled boiling, increases of the mass flux only result in a slight improvement of the heat transfer. Higher inlet subcooling, higher system pressure and smaller channel diameter lead to better boiling heat transfer. Experimental heat transfer coefficients are compared to predictions from classical correlations available in the literature. None of them predicts the experimental data for all tested conditions.     

Bubbly flow measurements in hydraulic jumps with small inflow Froude numbers

The transition from supercritical to subcritical open channel flow is characterised by a strong dissipative mechanism called a hydraulic jump. A hydraulic jump is turbulent and associated with the development of large-scale turbulence and air entrainment. In the present study, some new physical experiments were conducted to characterise the bubbly flow region of hydraulic jumps with relatively small Froude numbers (2.4 < Fr₁ < 5.1) and relatively large Reynolds numbers (6.6 × 10⁴ < Re < 1.3 × 10⁵). The shape of the time-averaged free-surface profiles was well defined and the longitudinal profiles were in agreement with visual observations. The turbulent free-surface fluctuation profiles exhibited a peak of maximum intensity in the first half of the hydraulic jump roller, and the fluctuations exhibited some characteristic frequencies typically below 3 Hz. The air–water flow properties showed two characteristic regions: the shear layer region in the lower part of the flow and an upper free-surface region above. The air–water shear layer region was characterised by local maxima in terms of void fraction and bubble count rate. Other air–water flow characteristics were documented including the distributions of interfacial velocity and turbulence intensity. The probability distribution functions (PDF) of bubble chord time showed that the bubble chord times exhibited a broad spectrum, with a majority of bubble chord times between 0.5 and 2 ms. An analysis of the longitudinal air–water structure highlighted a significant proportion of bubbles travelling within a cluster structure.     

Laminar bubbly flow in an open capillary channel in microgravity

The study of a bubbly laminar two-phase flow in an open capillary channel under microgravity conditions was conducted aboard the sounding rocket, Texus-45. The channel consists of two parallel plates of width b = 25 mm and distance a = 10 mm. The flow along the length l = 80 mm is confined by a free surface on one side and a plate on the opposite side. The bubbles are injected at the nozzle of the capillary channel via six capillary tubes of 100 μm in inner diameter. Different liquid and gas flow rates were tested leading to different liquid free surface shape and bubble size.     

Determination of thermal conductivity and interfacial energy of solid Zn solution in the Zn-Al-Bi eutectic system

The equilibrated grain boundary groove shapes for solid Zn solution (Zn-3.0 at.% Al-0.3 at.% Bi) in equilibrium with the Zn-Al-Bi eutectic liquid (Zn-12.7 at.% Al-1.6 at.% Bi) have been observed from quenched sample with a radial heat flow apparatus. Gibbs-Thomson coefficient, solid-liquid interfacial energy and grain boundary energy for solid Zn solution in equilibrium with Al-Bi-Zn eutectic liquid have been determined to be (5.1 ± 0.4) × 10⁻⁸ K m, (80.1 ± 9.6) × 10⁻³ and (158.6 ± 20.6) × 10⁻³ J m⁻² from the observed grain boundary groove shapes, respectively. The thermal conductivity variation with temperature for solid Zn solution has been measure with radial heat flow apparatus and the value of thermal conductivity for solid Zn solution has been determined to be 135.68 W/km at the eutectic melting temperature. The thermal conductivity ratio of equilibrated eutectic liquid to solid Zn solution, R = K_L(Zn)/K_S(Zn) has also been measured to be 0.85 with Bridgman type solidification apparatus.     

Experimental studies of adiabatic flow boiling in fractal-like branching microchannels

Experimental results of adiabatic boiling of water flowing through a fractal-like branching microchannel network are presented and compared to numerical model simulations. The goal is to assess the ability of current pressure loss models applied to a bifurcating flow geometry. The fractal-like branching channel network is based on channel length and width ratios between adjacent branching levels of 2^−1/2. There are four branching sections for a total flow length of 18 mm, a channel height of 150 μm and a terminal channel width of 100 μm. The channels were Deep Reactive Ion Etched (DRIE) into a silicon disk. A Pyrex disk was anodically bonded to the silicon to form the channel top to allow visualization of the flow within the channels. The flow rates ranged from 100 to 225 g/min and the inlet subcooling levels varied from 0.5 to 6 °C. Pressure drop along the flow network and time averaged void fraction in each branching level were measured for each of the test conditions. The measured pressure drop ranged from 20 to 90 kPa, and the measured void fraction ranged from 0.3 to 0.9. The measured pressure drop results agree well with separated flow model predictions accounting for the varying flow geometry. The measured void fraction results followed the same trends as the model; however, the scatter in the experimental results is rather large.     

Two-phase frictional pressure drop multipliers for SUVA R-134a flowing in a rectangular duct

The adiabatic two-phase frictional multipliers for SUVA, R-134a flowing in a rectangular duct (with D_H = 4.8 mm) have been measured for three nominal system pressures (0.9 MPa, T_sat = 35.5 °C; 1.38 MPa, T_sat = 51.8 °C; and 2.41 MPa, T_sat = 75.9 °C) and three nominal mass fluxes (510, 1020 and 2040 kg/m²/s). The data is compared with several classical correlations to assess their predictive capabilities. The Lockhart–Martinelli model gives reasonable results at the lowest pressure and mass flux, near the operating range of most refrigeration systems, but gives increasingly poor comparisons as the pressure and mass flux are increased. The Chisholm B-coefficient model is found to best predict the data over the entire range of test conditions; however, there is significant disagreement at the highest pressure tested (with the model over predicting the data upwards of 100% for some cases). The data shows an increased tendency toward homogeneous flow as the pressure and flow rate are increased, and in fact the homogeneous model best predicts the bulk of the data at the highest pressure tested.     

Numerical modeling and experimental investigation of gas–liquid slug formation in a microchannel T-junction

Gas–liquid two-phase flow in a microfluidic T-junction with nearly square microchannels of 113 μm hydraulic diameter was investigated experimentally and numerically. Air and water superficial velocities were 0.018–0.791 m/s and 0.042–0.757 m/s, respectively. Three-dimensional modeling was performed with computational fluid dynamics (CFD) software FLUENT and the volume of fluid (VOF) model. Slug flow (snapping/breaking/jetting) and stratified flow were observed experimentally. Numerically predicted void fraction followed a linear relationship with the homogeneous void fraction, while experimental values depended on the superficial velocity ratio U_G/U_L. Higher experimental velocity slip caused by gas inlet pressure build-up and oscillation caused deviation from numerical predictions. Velocity slip was found to depend on the cross-sectional area coverage of the gas slug, the formation of a liquid film and the presence of liquid at the channel corners. Numerical modeling was found to require improvement to treat the contact angle and contact line slip, and could benefit from the use of a dynamic boundary condition to simulate the compressible gas phase inlet reservoir.     

Numerical modeling of fluid flow and heat transfer in a narrow Taylor-Couette-Poiseuille system

We consider turbulent flows in a differentially heated Taylor-Couette system with an axial Poiseuille flow. The numerical approach is based on the Reynolds Stress Modeling (RSM) of [Elena and Schiestel, 1996] and [Schiestel and Elena, 1997] widely validated in various rotor-stator cavities with throughflow ( [Poncet, 2005], [Poncet et al., 2005] and [Haddadi and Poncet, 2008]) and heat transfer (Poncet and Schiestel, 2007). To show the capability of the present code, our numerical predictions are compared very favorably to the velocity measurements of Escudier and Gouldson (1995) in the isothermal case, for both the mean and turbulent fields. The RSM model improves, in particular, the predictions of the k-ε model of Naser (1997). Then, the second order model is applied for a large range of rotational Reynolds (3744 ? Re_i ? 37,443) and Prandtl numbers (0.01 ? Pr ? 12), flow rate coefficient (0 ? C_w ? 30,000) in a very narrow cavity of radius ratio s = R_i/R_o = 0.961 and aspect ratio L = (R_o − R_i)/h = 0.013, where R_i and R_o are the radii of the inner and outer cylinders respectively and h is the cavity height. Temperature gradients are imposed between the incoming fluid and the inner and outer cylinders. The mean hydrodynamic and thermal fields reveal three distinct regions across the radial gap with a central region of almost constant axial and tangential mean velocities and constant mean temperature. Turbulence, which is weakly anisotropic, is mainly concentrated in that region and vanishes towards the cylinders. The mean velocity distributions are not clearly affected by the rotational Reynolds number and the flow rate coefficient. The effects of the flow parameters on the thermal field are more noticeable and considered in details. Correlations for the averaged Nusselt numbers along both cylinders are finally provided according to the flow control parameters Re_i, C_w, and Pr.     

Nucleate boiling and critical heat flux of HFE-7100 in horizontal narrow spaces

The pool boiling heat transfer and critical heat flux CHF of saturated HFE-7100 at atmospheric pressure on a confined smooth copper surface were experimentally studied. The horizontal upward boiling surface was confined by a face-to-face parallel unheated surface. We analysed the effects obtained by changing the diameter of the unheated surface and the gap between the boiling surface and the adiabatic surface. The gap values investigated were s = 0.5, 1.0, 2.0, 3.5 mm. To confine the circular boiling surface (d = 30 mm), two different Plexiglas discs were used: one with a diameter D = 30 mm, equal to that of the copper boiling surface, and the other with a diameter D = 60 mm, equal to that of the overall test section support. For each configuration, boiling curves were obtained up to the thermal crisis. For both configurations, it was observed that, at low wall superheat, the effect of confinement was not significant if Bo > 1, while for Bo ? 1 the heat transfer coefficient increased as the channel width s decreased. By contrast, at high wall superheat, a drastic reduction in both heat transfer and CHF was seen when the channel width s decreased; this reduction was less pronounced when the smaller confinement disc (D = 30 mm) was used. CHF data were also compared with the values predicted by literature correlations.     

Enhanced nucleate boiling on copper micro-porous surfaces

Saturation boiling of PF-5060 dielectric liquid on Cu micro-porous surface layers (95, 139, 171, 197 and 220-μm thick) is investigated. These layers are deposited on 10 × 10 mm Cu substrates using two-stage electrochemical process. The basic micro-structure, obtained in the first stage using current density of 3 A/cm² for 15–44 s, depending on thickness, is strengthened by continuing electrochemical deposition using much lower current density for 10’s of minutes. For conditioned surface layers, after a few successive boiling tests, the pool boiling curves are reproducible and the temperature excursion prior to boiling incipience is either eliminated or reduced <7 K. Present nucleate boiling results are markedly better than those reported for dielectric liquids on micro- and macro-structured surfaces. Present values of CHF (22.7–27.8 W/cm²) and h_MNB (2.05–13.5 W/cm² K) are ∼40–70% higher than and >17 times those reported on plane surfaces (<16 W/cm² and ∼0.8 W/cm² K). Best results are those of the 171-μm thick layer: CHF of 27.8 W/cm² occurs at ΔT_sat of only 2.1 K and h_MNB of 13.5 W/cm² K occurs at ΔT_sat = 2.0 K.     

Analytical and level-set method based numerical study on oil-water smooth/wavy stratified-flow in an inclined plane-channel

Level-set method based transient 2D simulation of developing oil-water smooth-stratified (SS) and wavy-stratified (WS) flow in a horizontal and inclined plane-channel is done; for various inlet-velocity (u_in), inlet-interface-height (H_in), inclination-angle (θ), reduced surface-tension (σ ? σ_ow) and reduced gravity (g ? g_e). At the certain critical value of the governing parameters, SS to WS flow transition is captured, analyzed and reasoned. Increase in u_in, H_in and θ and a decrease in σ_ow and g_e are found to destabilize the SS flow. For fully-developed SS flow, a detailed analytical solution of interface-height, maximum axial-velocity, its transverse location, pressure-gradient and wall-shear stress is proposed for an inclined channel; an excellent agreement between the present analytical and numerical results is also reported. The SS flow analytical-results are also compared with the time-averaged WS flow numerical-results (near the channel-outlet), to understand the reasons for flow-transition. Flow development is studied with the help of axial variation of interface-height and maximum (over the cross-section of the channel) axial velocity; time-averaged for WS flow. Furthermore, the variation of development-length for SS flow and WS flow is studied. Finally, stretching of interface-area due to onset of WS flow is presented with the help of interfacial-area-concentration. Its calculation directly from the Dirac-delta function of the level set method is a novel-contribution.     

Deformation behavior and microstructure/texture evolution of an annealed 304 AISI stainless steel sheet. Experimental and micromechanical modeling

Different tensile tests are performed at −60 °C, on a 304 AISI stainless steel, to produce strain induced α′ martensite. Using EBSD analysis and X-ray diffraction methods, the corresponding texture and microstructure evolutions is studied, as well as the γ → α′ transformation mechanism. It is shown that α′ martensite is associated with {1 1 1}_γ faulted bands, partially ε bands, as often reported in the literature for low SFE stainless steels. As a consequence, these deformation bands play a key role in the nucleation and growth of α′ martensite. A micromechanical model is applied to simulate the deformation behavior of the stainless steel as well as the corresponding transformation kinetic and γ texture evolution. Different simulations are proposed, using various assumptions for the γ → α′ transformation mechanism. The simulation data are in better agreement with the experimental ones, when the γ → α′ transformation strain is derived from the Bowles–MacKenzie theory using the (1 1 1)_γ[−1 2 −1]_γ stacking fault shear system as lattice invariant shear.     

Nitrogen/non-Newtonian fluid two-phase upward flow in non-circular microchannels

This paper presents experimental investigations on nitrogen/non-Newtonian fluid two-phase flow in vertical noncircular microchannels, which have square or triangular cross-section with the hydraulic diameters being D_h = 2.5, 2.886 and 0.866 mm, respectively, by visualization method. Three non-Newtonian aqueous solutions with typical rheological properties, i.e., 0.4% carboxymethyl cellulose (CMC), 0.2% polyacrylamide (PAM) and 0.2% xanthan gum (XG) are chosen as the working fluids. The common flow patterns are identified as slug flow, churn flow and annular flow. The dispersed bubble flow is only found in the case with nitrogen/CMC solution two-phase flow in the largest channel. A new flow pattern of nitrogen/PAM solution two-phase flow, named chained bubble/slug flow, is observed in all the test channels. The flow regime maps are also developed and the results show that the rheological properties of the non-Newtonian fluid have remarkable influence on the flow pattern transitions. The geometrical factors of the microchannel such as the cross-section shape and hydraulic diameter of the channel can also affect the flow regime map. Finally, the results obtained in this work are compared with the available flow pattern transitions.     

Experimental investigation of initial and subsequent yield surfaces for laminated metal matrix composites

The aim of this work is to construct yield surfaces to describe initial yielding and characterize hardening behavior of a highly anisotropic material. A methodology for constructing yield surfaces for isotropic materials using axial–torsion loading is extended to highly anisotropic materials. The technique uses a sensitive definition of yielding based on permanent strain rather than offset strain, and enables multiple yield points and multiple yield surfaces to be conducted on a single specimen. A target value of 20 × 10⁻⁶ is used for Al₂O₃ fiber reinforced aluminum laminates having a fiber volume fraction of 0.55. Sixteen radial probes are used to define the yield locus in the axial–shear stress plane. Initial yield surfaces for [0₄], [90₄], and [0/90]₂ fibrous aluminum laminates are well described by ellipses in the axial–shear stress plane having aspect ratios of 10, 2.5, and 3.3, respectively. For reference, the aspect ratio of the Mises ellipse for an isotropic material is 1.73. Initial yield surfaces do not have a tension–compression asymmetry. Four overload profiles (plus, ex, hourglass, and zee) are applied to characterize hardening of a [0/90]₂ laminate by constructing 30 subsequent yield surfaces. Parameters to describe the center and axes of an ellipse are regressed to the yield points. The results clearly indicate that kinematic hardening dominates so that material state evolution can be described by tracking the center of the yield locus. For a nonproportional overload of (σ, τ) = (500, 70) MPa, the center of the yield locus translated to (σ, τ) = (430, 37) MPa and the ellipse major axis was only 110 MPa.     

Macro-to-microchannel transition in two-phase flow: Part 1 - Two-phase flow patterns and film thickness measurements

The classification of macroscale, mesoscale and microscale channels with respect to two-phase processes is still an open question. The main objective of this study focuses on investigating the macro-to-microscale transition during flow boiling in small scale channels of three different sizes with three different refrigerants over a range of saturation conditions to investigate the effects of channel confinement on two-phase flow patterns and liquid film stratification in a single circular horizontal channel (Part 2 covers the flow boiling heat transfer and critical heat flux). This paper presents the experimental two-phase flow pattern transition data together with a top/bottom liquid film thickness comparison for refrigerants R134a, R236fa and R245fa during flow boiling in small channels of 1.03, 2.20 and 3.04 mm diameter. Based on this work, an improved flow pattern map has been proposed by determining the flow patterns transitions existing under different conditions including the transition to macroscale slug/plug flow at a confinement number of Co ≈ 0.3-0.4. From the top/bottom liquid film thickness comparison results, it was observed that the gravity forces are fully suppressed and overcome by the surface tension and shear forces when the confinement number approaches 1, Co ≈ 1. Thus, as a new approximate rule, the lower threshold of macroscale flow is Co = 0.3-0.4 while the upper threshold of symmetric microscale flow is Co ≈ 1 with a transition (or mesoscale) region in-between.     

Effect of primary jet geometry on ejector performance: A cold-flow investigation

The following cold-flow study examines the interaction of the diffracted shock wave pattern and the resulting vortex loop emitted from a shock tube of various geometries, with an ejector having a round bell-shaped inlet. The focus of the study is to examine the performance of the ejector when using different jet geometries (primary flow) to entrain secondary flow through the ejector. These include two circular nozzles with internal diameters of 15 mm and 30 mm, two elliptical nozzles with minor to major axis ratios of a/b = 0.4 and 0.6 with b = 30 mm, a square nozzle with side lengths of 30 mm, and two exotic nozzles resembling a pair of lips with axis ratios of a/b = 0.2 and 0.5 with b = 30 mm. Shock tube driver pressures of P₄ = 4, 8, and 12 bar were studied, with the pressure of the shock tube driven section P₁ being atmospheric. High-speed schlieren photography using the Shimadzu Hypervision camera along with detailed pressure measurements along the ejector and the impulse created by the ejector were conducted.