Periodic flow boiling in a non-uniformly heated microchannel heat sink

Hydrodynamic and thermal characteristics of flow boiling in a non-uniformly heated microchannel were studied. Experiments were performed with a single microchannel and a series of microheaters to study the microscale boiling of water under axially non-uniform heat input conditions. A simultaneous real time visualization of the flow pattern was performed with the measurement of experimental parameters. Tests were performed over a mass flux of 309.8 kg/m² s, and heat flux of 200–600 kW/m². Test results showed different fluctuations of heated wall temperature, pressure drop, and mass flux with variations of the heat input along the flow direction. The unique periodic flow boiling in a single microchannel was observed at all heat flux conditions except for the increasing heat input distribution case which is the nearly uniform effective heat input distribution condition. The instability is correlated with flow pattern transition. For the nearly uniform effective heating condition, no fluctuation of the wall temperature, pressure drop, or mass flux was observed. We can relieve the instability by increasing total heat input along the flow direction and predict the instability using the transition criteria and flow pattern map.     

Carbon dioxide flow boiling in a single microchannel - Part II: Heat transfer

Flow boiling heat transfer coefficients of CO₂ have been measured in a single microchannel. Experiments were carried out in a horizontal stainless steel tube of 0.529 mm inner diameter, for three temperatures (−10, −5 and 0 °C), with the mass flux ranging from 200 to 1200 kg/m² s and the heat flux varying from 10 to 30 kW/m². The investigation covered qualities from zero to the dryout inception, i.e. pre-dryout conditions. Compared to larger microchannels and positive temperatures, a higher contribution of convective boiling was found, with a larger heat transfer coefficient than for pure nucleate boiling. Mainly two heat transfer regimes were found, depending on the boiling number (Bo). For Bo > 1.1 × 10⁻⁴, the heat transfer coefficient was highly dependent on the heat flux and moderately influenced by the quality and the mass flux. For Bo < 1.1 × 10⁻⁴, the heat transfer coefficient was hardly affected by the heat flux but strongly influenced by the quality and the mass flux. In addition, dryout results were reported. The effect of the mass flux on the dryout inception quality was found to be highly dependent on the heat flux and the saturation temperature.     

Experimental investigation of flow boiling characteristics in a cross-linked microchannel heat sink

This paper experimentally investigates flow boiling characteristics in a cross-linked microchannel heat sink at low mass fluxes and high heat fluxes. The heat sink consists of 45 straight microchannels each with a hydraulic diameter of 248 μm and heated length of 16 mm. Three cross-links, of width 500 μm, are introduced in the present microchannel heat sink to achieve better temperature uniformity and to avoid flow mal-distribution. Flow visualization, flow instability, two-phase pressure drop, and two-phase heat transfer measurements are conducted using the dielectric coolant FC-72 over a range of heat flux from 7.2 to 104.2 kW/m², mass flux from 99 to 290 kg/m² s, and exit quality from 0.01 to 0.71. Thermochromic liquid crystals are used in the present study as full-field surface temperature sensors to map the temperature distribution on the heat sink surface. Flow visualization studies indicate that the observed flow regime is primarily slug. Visual observations of flow patterns in the cross-links demonstrate that bubbles nucleate and grow rapidly on the surface of the cross-links and in the tangential direction at the microchannels’ entrance due to the effect of circulations generated in those regions. The two-phase pressure drop strongly increases with the exit quality, at x_e,o < 0.3, and the two-phase frictional pressure drop increases by a factor of 1.6–2 compared to the straight microchannel heat sink. The flow boiling heat transfer coefficient increases with increasing exit quality at a constant mass flux, which is caused by the dominance of the nucleation boiling mechanism in the cross-link region.     

An experimental investigation of flow boiling in an asymmetrically heated rectangular microchannel

By using unique experimental techniques and carefully constructed experimental apparatus, the characteristics of flow boiling of water in microscale were investigated using a single horizontal rectangular microchannel. A polydimethylsiloxane rectangular microchannel (D_h = 103.5 and 133 μm) was fabricated by using the replica molding technique, a kind of soft lithography. A piecewise serpentine platinum microheater array on a Pyrex substrate was fabricated with the surface micromachining MEMS technique. Real time flow visualization of the phase change phenomena inside the microchannel was performed using a high speed CCD camera with microscope. The experimental local boiling heat transfer coefficients were studied, and single bubble inception, growth, and departure, as well as elongated bubble behavior were analyzed to elucidate the microscale heat transfer mechanisms. Tests were performed for mass fluxes of 77.5, 154.9, and 309.8 kg/m² s and heat fluxes of 180–500 kW/m². The effects of mass flux, heat flux, and vapor qualities on flow boiling heat transfer in a microchannel were studied.     

Macro-to-microchannel transition in two-phase flow: Part 2 - Flow boiling heat transfer and critical heat flux

This part of the paper presents the current experimental flow boiling heat transfer and CHF data acquired for R134a, R236fa and R245fa in single, horizontal channels of 1.03, 2.20 and 3.04 mm diameters over a range of experimental conditions. The aim of this study is to investigate the effects of channel confinement, heat flux, flow pattern, saturation temperature, subcooling and working fluid properties on the two-phase heat transfer and CHF. Experimentally, it was observed that the flow boiling heat transfer coefficients are a significant function of the type of two-phase flow pattern. Furthermore, the monotonically increasing heat transfer coefficients at higher vapor qualities, corresponding to annular flow, signifies convective boiling as the dominant heat transfer mechanism in these small scale channels. The decreasing heat transfer trend at low vapor qualities in the slug flow (coalescing bubble dominated regime) was indicative of thin film evaporation with intermittent dry patch formation and rewetting at these conditions. The coalescing bubble flow heat transfer data were well predicted by the three-zone model when setting the dryout thickness to the measured surface roughness, indicating for the first time a roughness effect on the flow boiling heat transfer coefficient in this regime. The CHF data acquired during the experimental campaign indicated the influence of saturation temperature, mass velocity, channel confinement and fluid properties on CHF but no influence of inlet subcooling for the conditions tested. When globally comparing the CHF values for R134a in the 0.51-3.04 mm diameter channels, a peak in CHF peak was observed lying in between the 0.79 (Co ≈ 0.99) and 1.03 (Co ≈ 0.78) mm channels. A new CHF correlation has been proposed involving the confinement number, Co that is able to predict CHF for R134a, R236fa and R245fa in single-circular channels, rectangular multichannels and split flow rectangular multichannels. In summary, the present flow boiling and CHF trends point to a macro-to-microscale transition as indicated by the results presented in Ong and Thome (2011) [1].     

Enhanced heat transfer in confined pool boiling

We report the results of an experimental investigation of the heat transfer during nucleate boiling on a spatially confined boiling surface. The heat flux as a function of the boiling surface temperature was measured in pool boiling pots with diameters ranging from 15 mm down to 4.5 mm. It was found that a reduction of the pool diameter leads to an enhancement of the nucleate boiling heat flux for most of the boiling curve. Our experimental results indicate that this enhancement is not affected by the depth of the boiling pot, the material of the bounding wall, or the diameter of the inlet water supply. High-speed camera imaging shows that the heat transfer enhancement for the spatially confined pool boiling occurs in conjunction with a stable circulating flow, which is in contrast to the chaotic and mainly upward motion for boiling in larger pool diameters. An explanation for the enhancement of the heat transfer and the associated change in flow pattern is found in the singularisation of the nucleate boiling process.     

Experimental investigation of vapor bubble growth during flow boiling in a microchannel

Experiments were conducted to analyze flow boiling characteristics of water in a single brass microchannel of 25 mm length, 201 μm width, and 266 μm depth. Different heat flux conditions were tested for each of two different mass flow rates over three different values of inlet fluid temperature. Temporal and spatial surface temperature profiles were analyzed to show the relative effect of axial heat conduction on temperature rise along the channel length and the effect of flow regime transition on local surface temperature oscillation. Vapor bubble growth rate increased with increasing wall superheat. The slower a bubble grew, the further it was carried downstream by the moving liquid. Bubble growth was suppressed for increased mass flux while the vapor bubble was less than the channel diameter. The pressure spike of an elongating vapor bubble was shown to suppress the growth of a neighboring bubble by more than 50% of its volume. An upstream progression of the Onset of Bubble Elongation (OBE) was observed that began at the channel exit and progressed upstream. The effects of conjugate heat transfer were observed when different flow regime transitions produced different rates of progression for the elongation sequence. Instability was observed at lower heat fluxes for this single channel experiment than for similar studies with multiple channels.     

Two-phase flow and pool boiling heat transfer in microgravity

Researches on two-phase flow and pool boiling heat transfer in microgravity, which included ground-based tests, flight experiments, and theoretical analyses, were conducted in the National Microgravity Laboratory/CAS. A semi-theoretical Weber number model was proposed to predict the slug-to-annular flow transition of two-phase gas–liquid flows in microgravity, while the influence of the initial bubble size on the bubble-to-slug flow transition was investigated numerically using the Monte Carlo method. Two-phase flow pattern maps in microgravity were obtained in the experiments both aboard the Russian space station Mir and aboard IL-76 reduced gravity airplane. Mini-scale modeling was also used to simulate the behavior of microgravity two-phase flow on the ground. Pressure drops of two-phase flow in microgravity were also measured experimentally and correlated successfully based on its characteristics. Two space experiments on pool boiling phenomena in microgravity were performed aboard the Chinese recoverable satellites. Steady pool boiling of R113 on a thin wire with a temperature-controlled heating method was studied aboard RS-22, while quasi-steady pool boiling of FC-72 on a plate was studied aboard SJ-8. Ground-based experiments were also performed both in normal gravity and in short-term microgravity in the drop tower Beijing. Only slight enhancement of heat transfer was observed in the wire case, while enhancement in low heat flux and deterioration in high heat flux were observed in the plate case. Lateral motions of vapor bubbles were observed before their departure in microgravity. The relationship between bubble behavior and heat transfer on plate was analyzed. A semi-theoretical model was also proposed for predicting the bubble departure diameter during pool boiling on wires. The results obtained here are intended to become a powerful aid for further investigation in the present discipline and development of two-phase systems for space applications.     

Measurements and high-speed visualizations of flow boiling of a dielectric fluid in a silicon microchannel heat sink

Experiments were conducted to investigate flow boiling heat transfer to a dielectric fluid in a silicon chip-integrated microchannel heat sink. Twenty-four microchannels, each 389 μm × 389 μm in cross-section, were fabricated into the 12.7 mm × 12.7 mm silicon substrate. High-speed visualizations (at 12,500 frames per second) were performed simultaneously with heat transfer and pressure drop measurements to investigate the physics of flow boiling in parallel microchannel arrays. At low heat fluxes, bubbly flow is dominant, with the bubbles coalescing to form vapor slugs as the heat flux is increased. At high heat fluxes, the flow regimes in the downstream portion of the microchannels are characteristic of alternating wispy-annular flow and churn flow, while flow reversal is observed in the upstream region near the microchannel inlet. Local heat transfer measurements, obtained at three flow rates ranging from 35 to 60 ml/min, show that at lower heat fluxes, the heat transfer coefficient increases with increasing heat flux. The heat transfer coefficient in fully developed boiling is seen to be independent of flow rate in this range. At higher heat fluxes (exceeding 542, 673, 730 kW/m², respectively, for flow rates of 35, 47 and 60 ml/min), this trend is reversed, and the heat transfer coefficient decreases with further increases in heat flux due to partial dryout in some of the microchannels. Heat fluxes at which fully developed boiling is achieved depend on the flow rate. The pressure drop in fully developed boiling increases with increasing heat flux and is independent of flow rate for the test conditions considered in this work.     

Two-phase annular flow and evaporative heat transfer in a microchannel

A physical and mathematical model has been developed to predict the two-phase flow and heat transfer in a microchannel with evaporative heat transfer. Sample solutions to the model were obtained for both constant wall temperature and constant wall heat flux conditions. Results are provided for evaporation rate, liquid film thickness, liquid and vapor phase pressure and temperature distributions. In addition to the sample calculations that were used to illustrate the transport characteristics, computations based on the current model were performed to generate results for comparisons with the experimental results of Qu and Mudawar (2004) where two different mass flow rates of the working fluid were used in the experiment. The comparisons of total pressure drops with the experimental data of Qu and Mudawar (2004) cover the wall heat flux range of 142.71-240 W/cm² with a total channel mass flux of 400.1 kg/m² s and also the wall heat flu range of 99.54-204.39 W/cm² with total channel mass flux of 401.9 kg/m² s. The calculated results from the current model match closely with those of Qu and Mudawar (2004).     

Nucleate and transition boiling heat transfer under pool and external flow conditions

In this paper an overview of the boiling process, including recent advances made toward a mechanistic understanding of nucleate and transition boiling, is presented. Out of necessity, the review does not include boiling on enhanced surfaces or boiling of mixtures. Discussion of film boiling is also not included, as it is the subject of another review article. Only pool and external flow boiling of ordinary liquids are discussed. A few comments are made with respect to the theoretical and experimental studies that should be made in the future to further our understanding of the boiling process.     

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.     

A fractal analysis of subcooled flow boiling heat transfer

A fractal model for the subcooled flow boiling heat transfer is proposed in this paper. The analytical expressions for the subcooled flow boiling heat transfer are derived based on the fractal distribution of nucleation sites on boiling surfaces. The proposed fractal model for the subcooled flow boiling heat transfer is found to be a function of wall superheat, liquid subcooling, bulk velocity of fluid (or Reynolds number), fractal dimension, the minimum and maximum active cavity size, the contact angle and physical properties of fluid. No additional/new empirical constant is introduced, and the proposed model contains less empirical constants than the conventional models. The proposed model takes into account all the possible mechanisms for subcooled flow boiling heat transfer. The model predictions are compared with the existing experimental data, and fair agreement between the model predictions and experimental data is found for different bulk flow rates.     

Low-GWP refrigerants flow boiling heat transfer in a 5 PPI copper foam

This paper reports an experimental investigation of the heat transfer performance of the new low-GWP refrigerants, R1234yf and R1234ze(E), during flow boiling heat transfer inside a horizontal high porosity copper foam with 5 Pores Per Inch (PPI). Metal foams are a class of cellular structured materials consisting of a stochastic distribution of interconnected pores; these materials have been proposed as effective solutions for heat transfer enhancement during both single and two-phase heat transfer. R1234yf and R1234ze(E) refrigerants are appealing alternatives of the more traditional R134a by virtue of their negligible values of GWP and normal boiling temperatures close to that of R134a, which make them suitable solution in several different applications, such as: refrigeration and air conditioning and electronic thermal management. This work compares the two-phase heat transfer behaviour of these new HFO refrigerants, studying the boiling process inside a porous medium and permitting to understand their effective heat transfer capabilities. The experimental measurements were carried out by imposing three different heat fluxes: 50, 75, and 100 kW m⁻², at a constant saturation temperature of 30 °C; the refrigerant mass velocity was varied between 50 and 200 kg m⁻² s⁻¹, whilst the mean vapour quality varied from 0.2 to 0.95. The two-phase heat transfer and pressure drop performance of the two new HFO refrigerants is compared against that of the more traditional R134a.     

Status of prediction methods for critical heat fluxes in mini and microchannels

Saturated critical heat flux (CHF) is an important issue during flow boiling in mini and microchannels. To determine the best prediction method available in the literature, 2996 data points from 19 different laboratories have been collected since 1958. The database includes nine different fluids (R-134a, R-245fa, R-236fa, R-123, R-32, R-113, nitrogen, CO₂ and water) for a wide range of experimental conditions. This database has been compared to 6 different correlations and 1 theoretically based model. For predicting the non-aqueous fluids, the theoretical model by Revellin and Thome [Revellin, R., Thome, J.R., 2008. A theoretical model for the prediction of the critical heat flux in heated microchannels. Int. J. Heat Mass Transfer 51, 1216–1225] is the best method. It predicts 86% of the CHF data for non-aqueous fluids within a 30% error band. The data for water are best predicted by the correlation by Zhang et al. [Zhang, W., Hibiki, T., Mishima, K., Mi, Y., 2006. Correlation of critical heat flux for flow boiling of water in minichannels. Int. J. Heat Mass Transfer 49, 1058–1072]. This method predicts 83% of the CHF data for water within a 30% error band. Some suggestions have also been proposed in this paper for the future studies.     

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.     

Flow boiling enhancement of FC-72 from microporous surfaces in minichannels

The microporous coatings can remarkably enhance the liquid boiling heat transfer. Therefore, they are promising to be introduced into minichannels in the design of the cooling system of high-power microchips. However, the flow boiling heat transfer characteristics from microporous surfaces in the minichannels have not been extensively studied, and the pertinent knowledge is rather fragmentary. The present research is an experimental investigation on flow boiling of a dielectric fluid FC-72 from microporous coating surfaces in horizontal, rectangular minichannels of 0.49, 0.93 and 1.26 mm hydraulic diameter. Effects of coating structural parameters, such as the particle diameter and coating thickness, were investigated to identify the optimum microporous coating for heat transfer enhancement. All microporous surfaces in this paper were found to significantly enhance FC-72 flow boiling heat transfer in minichannels. With the optimum coating, the heat transfer coefficients could be 7-10 times those of the uncoated surface, and the boiling wall temperature was reduced by about 10 K. The flow boiling phenomena in the present minichannels were distinctly different from those in conventional-sized channels, due to the wall confinement effect on vapor bubbles. The confinement effect was evaluated by taking the contributions of the liquid mass flux and channel size into consideration. It was found that the very strong confinement effect was unfavorable with respect to flow boiling enhancement of the microporous coatings in the minichannels.     

Flow boiling heat transfer characteristics of R123 and R134a in a micro-channel

Flow boiling heat transfer in a single circular micro-channel of 0.19 mm ID has been experimentally investigated with R123 and R134a for various experimental conditions: heat fluxes (10, 15, 20 kW/m²), mass velocities (314, 392, 470 kg/m² s), vapor qualities (0.2–0.85) and different saturation pressures (158, 208 kPa for R123; 900, 1100 kPa for R134a). The heat transfer trends between R123 and R134a are clearly distinguished. Whether nucleate boiling is suppressed at low vapor quality or not determines the heat transfer trend and mechanism in the flow boiling of micro-channels. High convective heat transfer coefficients in the two-phase flow of micro-channels enables nucleate boiling to be suppressed even at low vapor quality, depending on the wall superheat requirement for nucleate boiling. In the case of early suppression of nucleate boiling, specifically R123, heat transfer is dominated by evaporation of thin liquid films around elongated bubbles. In the contrary case, namely R134a, nucleate boiling is dominant heat transfer mechanism until its suppression at high vapor quality and then two-phase forced convection heat transfer becomes dominant. It is similar to the heat transfer characteristic of macro-channels except the enhancement of nucleate boiling and the short forced convection region.     

Flow pattern and boiling heat transfer of CO2 in horizontal small-bore tubes

Increasing attention has been focused on carbon dioxide (CO₂) heat pump system where the temperature level is rather low, while the operating pressure is rather high. In this system, the density difference between vapor and liquid becomes rather small, which significantly affects flow patterns. Low surface tension and latent heat also have significant influence on two-phase flow patterns and heat transfer. This paper describes experimental and numerical investigation on flow patterns and heat transfer characteristics of boiling flow CO₂ at high pressure in horizontal small-bore tubes ranging from 1.0 mm to 3.0 mm I.D. Even though the density difference is rather small at high pressure, phase stratification takes place, which leads to the intermittent dryout at the upper wall. So far developed discrete bubble model by the authors for vertical flows is modified so as to include horizontal flow mechanisms. The predicted flow patterns with this new model agree on the whole with the experimental observation.     

Seed bubbles stabilize flow and heat transfer in parallel microchannels

Seed bubbles are generated on microheaters located at the microchannel upstream and driven by a pulse voltage signal, to improve flow and heat transfer performance in microchannels. The present study investigates how seed bubbles stabilize flow and heat transfer in micro-boiling systems. For the forced convection flow, when heat flux at the wall surface is continuously increased, flow instability is self-sustained in microchannels with large oscillation amplitudes and long periods. Introduction of seed bubbles in time sequence improves flow and heat transfer performance significantly. Low frequency (∼10 Hz) seed bubbles not only decrease oscillation amplitudes of pressure drops, fluid inlet and outlet temperatures and heating surface temperatures, but also shorten oscillation cycle periods. High frequency (∼100 Hz or high) seed bubbles completely suppress the flow instability and the heat transfer system displays stable parameters of pressure drops, fluid inlet and outlet temperatures and heating surface temperatures. Flow visualizations show that a quasi-stable boundary interface from spheric bubble to elongated bubble is maintained in a very narrow distance range at any time. The seed bubble technique almost does not increase the pressure drop across microsystems, which is thoroughly different from those reported in the literature. The higher the seed bubble frequency, the more decreased heating surface temperatures are. A saturation seed bubble frequency of 1000–2000 Hz can be reached, at which heat transfer enhancement attains the maximum degree, inferring a complete thermal equilibrium of vapor and liquid phases in microchannels. Benefits of the seed bubble technique are the stabilization of flow and heat transfer, decreasing heating surface temperatures and improving temperature uniformity of the heating surface.