Boiling in microchannels is a very efficient mode of heat transfer with high heat and mass transfer coefficients achieved. Less pumping power is required for two-phase flows than for single-phase liquid flows to achieve a given heat removal. Applications include electronics cooling such as cooling microchips in laptop computers, and process intensification with compact evaporators and heat exchangers. Evaporation of the liquid meniscus is the main contributor to the high heat fluxes achieved due to phase change at thin liquid films in a microchannel. The microscale hydrodynamic motion at the meniscus and the flow boiling heat transfer mechanisms in microchannels are not fully understood and are very different from those in macroscale flows. Flow instability phenomena are noted as the bubble diameter approaches the channel diameter. These instabilities need to be well understood and predicted due to their adverse effects on the heat transfer. A fundamental approach to the study of two-phase flow boiling in microchannels has been carried out. Simultaneous visualisation and hydrodynamic measurements were carried out investigating flow boiling instabilities in microchannels using two different working fluids (n-Pentane and FC-72). Rectangular, borosilicate microchannels of hydraulic diameter range 700-800 μm were used. The novel heating method, via electrical resistance through a transparent, metallic deposit on the microchannel walls, has enabled simultaneous heating and visualisation to be achieved. Images and video sequences have been recorded with both a high-speed camera and an IR camera. Bubble dynamics, bubble confinement and elongated bubble growth have been shown and correlated to the temporal pressure fluctuations. Both periodic and nonperiodic instabilities have been observed during flow boiling in the microchannel. Analysis of the IR images in conjunction with pressure drop readings, have allowed the correlation of the microchannel pressure drop to the wall temperature profile, during flow instabilities. Bubble size is an important parameter when understanding boiling characteristics and the dynamic bubble phenomena. In this thesis it has been demonstrated that the flow passage geometry and microchannel confinement effects have a significant impact on boiling, bubble generation and bubble growth during flow boiling in microchannels.

An acoustic field is used to increase the critical heat flux of a copper boiling heat transfer surface. The increase is a result of the acoustic effects on the vapor bubbles. Experiments are being performed to explore the effects of an acoustic field on vapor bubbles in the vicinity of a rigid heated wall. Work includes the construction of a novel heater used to produce a single vapor bubble of a prescribed size and at a prescribed location on a flat boiling surface for better study of an individual vapor bubble s reaction to the acoustic field. Work also includes application of the results from the single bubble heater to a calibrated copper heater used for quantifying the improvements in critical heat flux.

An experimental investigation was carried to examine the flow/ thermal field characteristics with/without phase change in the microchannels and compared with the traditional results. There are three parts in this study. The first part investigated the 2-D flow field measured by the micro particle image velocimetry (£gPIV) in a single PMMA microchannel fabricated by an ArF excimer laser. The slip boundary condition in the microchannel wall was also discussed. The second part studied the influence of surface condition (hydrophilic vs hydrophobic) on the flow/thermal field in a micro cooling device which included twenty parallel microchannels, which was fabricated by SU-8 microfabrication technique and replicated by the PDMS replica technique. The UV/ozone device was used to change the PDMS microchannels¡¦ surface condition from hydrophobic to hydrophilic and the £gPIV/£gLIF system was also used to measure the velocity and temperature distribution. The third part investigated the two-phase subcooled flow boiling phenomena (onset of nucleate boiling, boiling curve, flow patterns, bubble departure diameter and frequency) in the seventy-five parallel microchannels fabricated by SU-8 microfabrication technique, and aimed to raise the critical heat flux (CHF) and heat transfer coefficient to enhance the cooling efficiency. Three major methods were used in this study, as follows: (1) To add the cavity angle of £c = 60¢X, 90¢X, and 120¢X on the microchannel side walls. (2) To coat 2 £gm diamond film on the Cu heated surface. (3) To add 1 vol. % Multi-walled Carbon Nanotube (MCNT) into the working medium (deionized water). The goal of this paper is to develop a high heat flux cooling technique and apply the experimental results to solve the cooling problem resulting from the exceedingly high heat flux from the electronic component.

Modern nuclear reactors still use Zirconium-4 Alloy (Zircaloy®) as the cladding material for fuel elements. A substantial amount of research has been done to investigate the boiling heat transfer behind the cooling mechanism of the reactor. Boiling heat transfer is notoriously difficult to quantify in an acceptable manner and many empirical correlations have been derived in order to achieve some semblance of a mathematical model. It is well known that the surface conditions on the heat transfer surface plays a role in the formulation of the heat transfer coefficient but on the other hand it also has an effect on the pressure drop alongside the surface. It is therefore necessary to see whether there might be an optimum surface roughness that maximises heat transfer and still provides acceptably low pressure drop. The purpose of this study was to experimentally measure pressure drop and heat transfer associated with vertical heated tubes surrounded by flowing water in order to produce flow boiling heat transfer. The boiling heat transfer data was used to ascertain what surface roughness range would be best for everyday functioning of nuclear reactors. An experimental set-up was designed and built, which included a removable panel that could be used to secure a variety of rods with different surface roughnesses. The pressure drop, surface temperature, flow rate and heat input measurements were taken and captured in order to analyse the heat transfer and friction factors. Four rods were manufactured with different roughnesses along with a fifth rod, which remained standard. These rods were tested in the flow loop with water in the upward flow direction. Three different system mass flow rates were used: 0kg/s, 3.2kg/s and 6.4kg/s. Six repetitions were done on each rod for the tests; the first repetition was not used in the results since it served the purpose to deaerate the water in the flow loop. The full range of the power input was used for each repetition in the tests. For the heat transfer coefficient at a system mass flow rate of 3.2kg/s, satisfactory comparisons were made between the test results and those found in literature with an average deviation of 14.53%. At 6.4kg/s system mass flow rate the comparisons deviated on average 55.45%. The velocity of the fluid in the test section was calculated from the pressure drop and was validated using separate tests. The plain rod, with no added roughness, was found to be the optimal surface roughness which is what is used in industry today. The flow loop was in need of a couple of redesigns in order to produce more accurate results. Future work suggestions include adding more rods in the test section in order to investigate the nature of heat transfer in a rod bundle array as well as implementing all the suggested changes listed in the conclusion. / Dissertation (MEng)--University of Pretoria, 2017. / Mechanical and Aeronautical Engineering / MEng / Unrestricted

The current study is an experimental and analytical investigation of JIB within the nucleate and transition boiling regimes. This study focuses on studying JIB within the stagnation zone of a free water jet. An experimental setup has been designed and built at the Thermal Processing Laboratory (TPL) with the capability of carrying out boiling experiments at heat fluxes up to 12 MW/m2. The JIB curves have been obtained under steady-state conditions for a wide range of jet conditions, higher than those considered during previous JIB studies. The effect of jet velocity, up to 3.8 m/s, and degree of subcooling, up to 49 °C, on the JIB curve has been studied. The results showed that both jet velocity and degree of subcooling have a weak effect on the nucleate boiling regime and significantly affect the transition boiling regime. Bubble dynamics under the impinging jet within the nucleate boiling regime and the stability of the vapor layer within the transition boiling regime have been investigated. An analytical mechanistic model, based on force balance and thermal balance equations, has been developed to predict the bubble growth rate and the BDD. The developed model was validated using current experimental data. The model gave a relative deviation of 17.8 %. Results of the mechanistic model within the stagnation zone showed that, amongst the three heat transfer mechanisms that affect bubble growth (i.e., the microlayer evaporation, the heat from the superheated layer, the convection heat loss to subcooled liquid), the microlayer evaporation is the most significant contributor to the rate of bubble growth. The current work conducted within the transition boiling regime was focused on the determination of the total wall heat flux within the stagnation zone, both experimentally and analytically. Steady-state experiments have been carried out during which the vapor layer stability was examined. The vapor layer breakup frequency was measured using a fiber-optic probe. Experiments were conducted at a jet velocity of 1 m/s and degrees of subcooling between 11 and 49 ºC. / Thesis / Doctor of Philosophy (PhD)

Boiling heat transfer provides a means of removing high heat fluxes at low temperature differences in many applications in the power and process industries. A strong interest has been also developed for the cooling of silicon-based devices, such as electronic chips. However, a complete model to describe the processes involved has not been developed as yet. This PhD project focused on the study of nucleate pool boiling via numerical simulations for a solid plate horizontally immersed in a saturated liquid with a large number of potential nucleation sites. The simulations were developed by a FORTRAN code based on a hybrid approach, combining the 3-dimensional time-dependent solution for the temperature field on the substrate with semi-empirical models for phenomena occurring on the liquid side. The starting point of the project was the modification of a previous version of the code in order to reduce the computational time (in collaboration with Dr. Nelson at Los Alamos National Laboratory) and improve the modelling of the physics of the processes. One of the key features of the code is the flexibility in adapting to different conditions. In fact the code was used to study bubble growth, site activation frequency and superheat variations, as well as the interactions between nucleation sites. The differences in behaviour between very thin metal foils immersed in water and thicker silicon substrates in FC-72 were studied. The results were compared with experimental results produced at the University of Edinburgh and the University of Ljubljana, both partners of this project. Both the numerical and physical modifications introduced made it possible to have simulations for a large number of sites, of the order of 100, in reasonable times, of the order of days, so that the code can be now used as a tool for the design of new test sections.

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 { 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 oC 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%.

Pool boiling process is frequently encountered in a number of engineering applications. It is difficult to exactly predict the heat transfer coefficient. This is because the boiling phenomenon is rather complex and influenced by many factors, such as surface condition, heater size, geometry, material, arrangement of heated rods, and refrigerants, etc. The key boiling parameters (bubble dynamics data) such as bubble departure diameter, frequency, velocity and nucleation site density will be varied in such different heated surface resulting in the different effect of heat transfer. Furthermore, more fundamental of the physical phenomenon can be obtained. This study was performed experimentally. R-134a and R-600a were used as refrigerants. The surface condition will be changed with plasma spray coating. It is expected that the surface condition can affect the nucleate boiling heat transfer in certain degree. In addition, using the high speed digital vide camera and LDV to measure the bubble diameter and dynamics of R-600a and R-134a while growing. According of the results of experiments. The boiling curves in different situation were drawn and the influences of heat transfer coefficients by bubble velocity was also examinate. Finally, to broaden our basic understanding of different characteristics of refrigeration surface condition and heat transfer coefficient, thermal design data of a flooded type evaporator of high performance as well as more and further physical insight of the above-stated nucleate boiling heat transfer can be acquired. The results will hopefully be helpful not only for the academia but for the industry.

Thesis (M.S. in Mechanical Engineering)--Naval Postgraduate School, June 2003. / Thesis advisor(s): Ashok Gopinath. Includes bibliographical references (p. 31-32). Also available online.

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