Pool Boiling Enhancement Through Improved Liquid Supply Pathways Over Open Microchannels


Book Description

"Boiling is an efficacious mode of heat transfer and is utilized in various energy conversions, heat exchange systems and in cooling of high energy density electronic components. Fundamental pool boiling mechanisms suggest that liquid rewetting on a heated surface is a key factor in delaying critical heat flux (CHF) for enhancing pool boiling performance. In this study, pool boiling enhancement is achieved by providing improved liquid supply pathways to nucleation sites in open microchannels. A two part study is conducted to enhance pool boiling performance of open microchannels. Micromachined and porous surfaces are identified as enhancement techniques in Part-I and Part-II respectively. The results obtained in part-I showed significant improvement in the pool boiling performance when tested with water and FC-87. In part-II of the study, porous coatings are deposited on the boiling surface of an open parallel microchannel fin tops, channel bottoms and both, and individually investigated for their pool boiling performance. The best performing surface was with porous coatings throughout the geometry and had a CHF of 313 W/cm2 at a wall superheat of 7.5 °C. High speed images for the three surfaces show that bubble nucleation occurred at the location of porous deposits. Furthermore, additional nucleation sites are identified as the main contributing factor in the best performing surface which had an enhancement of 150% in CHF when compared to a plain surface. Efficient liquid recirculation provided by open microchannels also contributed to improved microconvection in the channels."--Abstract.




Enhanced Pool Boiling of Water with Open Microchannels Over Cylindrical Tubes


Book Description

"Pool boiling is a stable and efficient method for transferring large quantities of heat. It is employed in a wide range of applications, including steam generation in boilers, petrochemical, pharmaceutical, cryogenic and many other industrial processes. The objective of this work was to investigate the augmentation in the boiling heat transfer rates with an array of open microchannels over a cylindrical tube. In order to develop high performance surfaces, rectangular and V-groove cross-sectional geometry microchannels were fabricated and tested over tubular test sections. These microchannels were manufactured in two configurations: circumferentially around the test section and axially along the length. The effects of the microchannel geometric parameters on pool boiling performance were studied under horizontal and vertical orientations. Twenty uniquely modified microchannel surfaces were designed, fabricated and tested. The best performance was obtained with a circumferential rectangular microchannel test section in the horizontal orientation. A maximum heat transfer coefficient of 129 kW/m2*K was achieved at a heat flux of 1095 kW/m2, while maintaining a wall superheat of 8.5 K. The overall enhancement factors obtained at the maximum heat flux condition, ranged between 1.9 and 3.4 in the horizontal orientation, and 2.1 and 3.1 in the vertical orientation. The critical heat flux for almost all the designed test surfaces was increased by a factor of at least 1.6 over a plain tube. Area normalized results indicated that factors other than area enhancement are responsible for augmenting the heat transfer performance. High-speed videography of bubbles nucleating, growing and departing from the heated surface was performed. The bubble behavior over these open microchannels was analyzed to understand the fundamental mechanism during pool boiling. The bubble interactions in and over the open microchannels, and the liquid rewetting phenomenon greatly influence the heat transfer performance for these surface."--Abstract.




Additive Manufactured Microstructures and Designs for High Heat Flux Dissipation During Pool Boiling


Book Description

"Heat dissipation is vital in industries requiring predictable operating temperatures while also producing large heat fluxes. These industries include electronics and power generation. For electronics, as more devices fit on a smaller area, the heat flux increases dramatically. Pool boiling offers a solution to electronic cooling due to extremely high heat transfer with a low temperature change. Previous research has focused on coatings and precision manufacturing to create microchannels and features for boiling augmentation. However, this is limited to designs for subtractive processes. The use of additive manufacturing (AM) offers a novel way of thinking of design for boiling enhancement. 3-D boiling structures are fabricated out of aluminum using the Vader System's magnetojet printer. Three generations of geometric structures are created: a volcano-with-holes, a miniaturized volcano-with-holes, and a modular volcano-with-holes. These designs are not easily manufactured using standard techniques. As such, three-dimensional bubble dynamics are currently being explored using high speed imaging and particle image velocimetry. By printing a volcano shape with base holes, the liquid and vapor phases are physically separated in a process termed macroscale liquid-vapor pathways. The singular volcano-with-holes chips achieved a maximum heat flux of 217.3 W/cm2 with a maximum heat transfer coefficient (HTC) of 97.2 kW/m2K (81% improvement over plain). By producing four volcanoes on a single chip, the liquid flow length inside the volcano, which acts as the entrance length, is reduced by 50% and the HTC greatly increased. The highest performing miniaturized volcano-with-holes chip reached a maximum heat flux of 223.1W/cm2 with a maximum HTC of 139.1 kW/m2K (150% improvement over plain). Additionally, the highest performing miniaturized chip was printed on top of a microchannel array. This resulted in combined enhancement from both microchannel and bubble dynamics resulting in a maximum heat flux of 228.4 W/cm2 with a HTC of 339.6 kW/m2K (533% improvement over plain). Finally, a modular structure was created to determine the individual influence of conduction and bubble dynamic augmentation on boiling enhancement. The modular designs show an 83% improvement in CHF (202.4 W/cm2) over plain copper chips and a 83% improvement in HTC(139.0 kW/m2K). This indicates boiling enhancement arises from three-dimensional control over bubble dynamics, resulting in macroscale separate liquid-vapor pathways."--Abstract.







Multiscale Mechanistic Approach to Enhance Pool Boiling Performance for High Heat Flux Applications


Book Description

"The advent of cloud computing and the complex packaging architecture of next generation electronic devices drives methods for advanced thermal management solutions. Convection based single-phase cooling systems are inefficient due to their large pressure drops, fluid temperature differences and costs, and are incapable of meeting the cooling requirements in the high power density components and systems. Alternatively, phase-change cooling techniques are attractive due to their ability to remove large amounts of heat while maintaining uniform fluid temperatures. Pool boiling heat transfer mechanism centers on the nucleation, growth and departure of a bubble from the heat transfer surface in a stagnant pool of liquid. The pool boiling performance is quantified by the Critical Heat Flux (CHF) and Heat Transfer Coefficients (HTC) which dictate the operating ranges and efficiency of the heat transfer process. In this work, three novel geometries are introduced to modify the nucleation characteristics, liquid pathways and contact line motion on the prime heater surface for a simultaneous increase in CHF and HTC. First, sintered microchannels and nucleating region with feeder channels (NRFC) were developed through the mechanistic concept of separate liquid-vapor pathways and enhanced macroconvection heat transfer. A maximum CHF of 420 W/cm2 at a wall superheat of 1.7 °C with a HTC of 2900 MW/m2°C was achieved with the sintered-channels configuration, while the NRFC reached a CHF of 394 W/cm2 with a HTC of 713 kW/m2°C. Second, the scale effect of liquid wettability, roughness and microlayer evaporation was exploited to facilitate capillary wicking in graphene through interlaced porous copper particles. A CHF of 220 W/cm2 with a HTC of 155 kW/m2°C was achieved using an electrodeposition coating technique. Third, the chemical heterogeneity on nanoscale coatings was shown to increase the contribution from transient conduction mechanisms. A maximum CHF of 226 W/cm2 with a HTC of 107 kW/m2°C was achieved. The enhancement techniques developed here provide a mechanistic tool at the microscale and nanoscale to increase the boiling CHF and HTC."--Abstract.




Experimental Investigation of Pool Boiling Performance with Ethanol and FC-87 on Open Microchannel Surfaces


Book Description

"The growing trend in miniaturization of electronics has generated a need for efficient thermal management of these devices. Boiling has the ability to dissipate large quantity of heat while maintaining a small temperature difference. Vapor chamber with pool boiling offers an effective way to provide cooling and maintaining temperature uniformity. The objective of the current work is to investigate pool boiling performance of ethanol and FC-87 on microchannel surfaces. Ethanol is an attractive working fluid due to its better heat transfer performance and higher heat of vaporization compared to refrigerants, and lower boiling point compared to water. The saturation temperature of ethanol can be further reduced to temperatures suitable for electronics cooling by lowering the system pressure. Fluorocarbons are considered to be ideal fluids for electronics cooling due to their low normal boiling point, dielectric and inert nature. FC-87 is selected for the current work. Ethanol is tested at four different absolute pressures, 101.3 kPa, 66.7 kPa, 33.3 kPa and 16.7 kPa using different microchannel surface configurations. Heat dissipation in excess of 900 kW/m2 was obtained while maintaining the wall surface below 85°C at 33 kPa. Flammability, toxicity and temperature overshoot issues need to be addressed before practical implementation of ethanol-based cooling systems in electronics cooling application. FC-87 with microchannel yields average performance when compared to literature. Effect of surface area is identified as the key reason for performance enhancement. A new finned structure is developed, which gave a heat flux value 1.25 MW/m2 at 40°C wall superheat for FC-87 at atmospheric conditions."--Abstract.




Pool Boiling from Enhanced Structures Under Confinement


Book Description

A study of pool boiling of a dielectric liquid (PF 5060) from single-layered enhanced structures was conducted. The parameters investigated were the heat flux, the width of the microchannels and the microchannel pitch. The boiling performance of the enhanced structures increases with increase in channel width and decrease in channel pitch. Simple single line curve fits are provided as a practical way of predicting the data over the entire nucleate boiling regime. The influence of confinement on the thermal performance of the enhanced structures was also assessed. The main parameter investigated was the top space (0 mm 3{13 mm). High-speed visualization was used as a tool . For the total confinement (= 0 mm), the heat transfer performance of the enhanced structures was found to depend weakly on the channel width. For>0 mm, the enhancement observed for plain surfaces in the low heat fluxes regime is not present for the present enhanced structure. The maximum heat flux for a prescribed 85 °C surface temperature limit increased with the increase of the top spacing, similar to the plain surfaces case. Two characteristic regimes of pool boiling have been identified and described: isolated flattened bubbles regime and coalesced bubbles regime. A semi-analytical predictive model applicable to pool boiling under confinement is developed. The model requires a limited number of empirical constants and is capable of predicting the experimental heat flux within 30%.




High-pressure Pool-boiling Heat Transfer Enhancement and Mechanism on Engineered Surfaces


Book Description

Boiling has received considerable attention in the technology advancement of electronics cooling for high-performance computing applications. Two-phase cooling has an advantage over a single-phase cooling in the high heat removal rate with a small thermal gradient due to the latent heat of vaporization. Many surface modifications have been done in the past including surface roughness, mixed wettability and, porous wick copper play a crucial role in the liquid-vapor phase change heat transfer. However, the mechanisms of high-pressure pool-boiling heat transfer enhancement due to surface modifications has not been well studied or understood. The properties of water, such as the latent heat of vaporization, surface tension, the difference in specific volume of liquid and vapor, decrease at high-pressure. High-pressure pool-boiling heat transfer enhancement is studied fundamentally on various engineered surfaces. The boiling tests are performed at a maximum pressure of 90 psig (620.5 kPa) and then compared to results at 0 psig (0 kPa). The results indicate that the pressure influences the boiling performance through changes in bubble dynamics. The bubble departure diameter, bubble departure frequency, and the active nucleation sites change with pressure. The pool-boiling heat transfer enhancement of a Teflon© coated surface is also experimentally tested, using water as the working fluid. The boiling results are compared with a plain surface at two different pressures, 30 and 45 psig. The maximum heat transfer enhancement is found at the low heat fluxes. At high heat fluxes, a negligible effect is observed in HTC. The primary reasons for the HTC enhancement at low heat fluxes are active nucleation sites at low wall superheat and bubble departure size. The Teflon© coated surface promotes nucleation because of the lower surface energy requirement. The boiling results are also obtained for wick surfaces. The wick surfaces are fabricated using a sintering process. The boiling results are compared with a plain surface. The reasons for enhancements in the pool-boiling performance are primarily due to increased bubble generation, higher bubble release frequency, reduced thermal-hydraulic length modulation, and enhanced thermal conductivity due to the sintered wick layer. The analysis suggests that the Rayleigh-critical wavelength decreases by 4.67 % of varying pressure, which may cause the bubble pinning between the gaps of sintered particles and avoids the bubble coalescence. Changes in the pitch distance indicate that a liquid-vapor phase separation happens at the solid/liquid interface, which impacts the heat-transfer performance significantly. Similarly, the role of the high-pressure over the wicking layer is further analyzed and studied. It is found that the critical flow length, [lambda]u reduces by three times with 200 [mu]m particles. The results suggest that the porous wick layer provides a capillary-assist to liquid flow effect, and delays the surface dry out. The surface modification and the pressure amplify the boiling heat transfer performance. All these reasons may contribute to the CHF, and HTC enhancement in the wicking layer at high-pressure.




Directional Notches as Microstructures to Promote Nucleation and Heat Transfer in Pool Boiling


Book Description

"Heat generation in electronic hardware has become a major limiting factor in achieving maximum efficiency in modern computer parts. Classically forced flow convection systems are used to remove this heat at high rates but can be costly to implement and can take up space that may be needed for other critical components. In response to this, systems that use fewer parts scale in compact spaces are needed. In these situations, pool boiling as a heat transfer mechanism can excel. Pool boiling removes heat through the evaporation of fluid. On a flat surface pool boiling is chaotic and this random nature may hinder its ability to remove heat as effectively. The surface geometry of a pool boiling system can be altered to direct the flow of generated vapor bubbles to allow for increased heat flow and higher heat transfer performance. By creating paths for the vapor to follow we can induce currents in the flow of cool fluid to the heater surface, creating a faster cycle of vapor production therefore cooling the heated surface at a faster rate. The purpose of this study is to investigate angled chip notches as an alternative to already existing high heat transfer surfaces in pool boiling. These alternative chips may prove cheaper or easier to produce the alternative which may incorporate fine, hard to produce features or post process coatings like sintering and the addition of hydrophobic materials. This study will examine the effect these specifically designed notches have on the interaction between the directed vapor and the liquid pathways they create. By creating notches in the surface of the chip, vapor bubble is given sites to nucleate and form vapor pathways. The angle walls on the one side of the notch will act as a wedge when water being driven toward the notch pushes the nucleating bubble up and out of the notch. Combined with pairing nucleating notches up with another oppositely facing one the vapor bubble is departing earlier then it would have had it not been assisted by these surface elements. With just these paired notches placed in row, an HTC improvement of 158% was recorded, compared to a plain copper surface. With the inclusion of microchannels this improvement was brought up to 161%"--Abstract.




Influence of Liquid Height on Pool Boiling Heat Transfer


Book Description

"As technology advances due to continuous research, devices are becoming more compact, efficient, and powerful. Therefore, heat rejection from such devices becomes ever so critical to maximizing their potential. Compared to other heat extraction methods, boiling provides one of the highest heat transfer coefficients. The heat extraction due to the boiling process is limited to the Critical Heat Flux (CHF). At CHF, an insulating layer of escaping bubbles forms upon the surface to prevent boiling continuity. Subsequently, the surface temperature increases uncontrollably, leading to a system failure. Hence, the elevation of CHF is critical to boiling enhancement. Improvements to the heat transfer process can be made with either surface manipulation or liquid manipulation. Based on previous studies, it is found that the removal of bubbles from the heater surface is critical to enhancing performance. Therefore, it is hypothesized that if a bubble can be encouraged to reach liquid-gas the interface quickly, gains in the boiling performance can be achieved. Due to the vapor bubble's movement in liquid bulk, it becomes critical to understand the influence of liquid height on pool boiling for enhancement. While pool boiling enhancement using heating surface modification is extensively studied and documented, there is a research gap between understanding the effect of liquid height at high heat fluxes. Thus, this study tries to evaluate the influence of liquid height on pool boiling performance at higher heat fluxes and identify the underlying bubble movement mechanism. It is observed that as CHF increases with liquid height. Moreover, it is observed that bubble movement is more effortless at low liquid height resulting in higher HTC. On the other hand, larger liquid height provides improved rewetting of the surface resulting in higher CHF. Upon analysis of high-speed recording of the escaping bubbles, it was observed that the maximum heat transfer coefficient is observed when the liquid height is about four times the height of the departing bubble diameter."--Abstract.