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Trends towards miniaturizing the electronics devices and to increase the computational capability has driven the modern microelectronics industry toa state where efficient thermal management issue has become the most challenging and in some case limiting parameter for the further development of these devices. Research is going on around the globe to address this challenge and to come up with a solution that is economically viable and user level applicable to meet not only the current issue but also to address the forth coming heat removal challenges where 1000 W/cm 2 seems to be a feasible target specially for the defense related electronics. Exploiting high surface area to volume ratio and high latent heat of vaporization, flow boiling in microchannel possesses the highest opportunityto meet this challenge; although boiling instability and pressure fluctuation limit its implementation in any practical devices. To harness the full potential of flow boiling in microchannel, new schemes need to be implemented to control the boiling characteristics. This paper presents one active (implementation of synthetic jet in microchannel) and one passive (surface morphology modification with nanostructures) flow boiling control mechanism which can be implemented easily and can tune all the boiling performance parameters positively. Flow boiling in microchannel with reliable control mechanism could be the solution for the next generationthermal management challenges arising from the microelectronics industry. [ABSTRACT FROM AUTHOR]

Abstract: Flow boiling performance of a Cu microchannel coated with Al2O3 nanoparticle has been investigated experimentally. Experiments were performed in a single microchannel having hydraulic diameter of 672μm using de-ionized (DI) water as the coolant. Surface morphology of the microchannel was modified by depositing nanoparticles through pool boiling of ethanol based alumina (Al2O3) nanofluid. Flow boiling, along with single-phase convective heat transfer experiments were performed at different mass flux and different inlet sub-cooling. Results from the microchannel with bare surface are used as the reference data. Nanoparticles deposited surface was found effective in enhancing the critical heat flux (CHF); up to 39% enhancement in CHF was observed in this experimental range. However, the heat transfer coefficient (HTC) was observed to be reduced marginally for the nanoparticles coated surface compared with the bare surface. [Copyright &y& Elsevier]

Extensive experimental investigations along with high speed visualizations have been performed to assess the flow boiling characteristics in Silicon Nanowire (SiNW) microchannels. Experiments have been also performed in Plainwall microchannels to compare their performances with SiNW configurations. HFE-7100 has been used as the working fluid and experiments are conducted in a forced convection loop at mass flux range of 400–1600 kg/m 2 s. Arrays of microchannel consist 5 (five) parallel straight microchannels with Width, Depth and Length dimension of 220 μm, 250 μm and 10 mm respectively. Flow boiling performances including heat transfer coefficient (HTC), pressure drop, two-phase flow instabilities and critical heat flux (CHF) have been studied in both the Silicon plainwall (smooth inner surface) and Silicon Nanowire (silicon nanostructured inner surface) microchannels. High speed flow visualizations have been performed at up to 70,000 frames per s (fps) to understand the difference in boiling mechanisms between Plainwall and SiNW. SiNW performs significantly enhanced HTC (up to 400% improvement), reduces flow boiling instabilities and pressure drop (up to 70% reduction) compared to Plainwall microchannels. However, little/insignificant effect of nanostructured surface has been observed on CHF. In addition, a major difference in two-phase flow regime development has been observed between the SiNW and Plainwall microchannels during flow visualization. Specifically, SiNWs introduce explosive bubble nucleation, reduce intermittent flow regimes (slug/churn), improve rewetting, maintain thin liquid film and thus, improve system performances. [ABSTRACT FROM AUTHOR]

Enhancing critical heat flux (CHF) of flow boiling without escalating pressure drop is highly desirable in thermal management of high power-density electronic devices. Usually, an improved CHF can be achieved by restricting flow or at a higher mass velocity, leading to a higher pressure drop. In this study, compared to the two-nozzle microchannel configuration, the improved microchannel configuration as detailed in the Part (I) of this study can enhance CHF without sacrificing pressure drop. In this part, CHF is experimentally evaluated together with the pressure drop with mass flux ranging from 120 kg/m 2 s to 600 kg/m 2 s. Compared to the two-nozzle configuration, our study shows that CHF can be enhanced up to 32% with a ∼53% reduction of pressure drop at a mass flux of 325 kg/m 2 s. The bubble collapse-removal process is significantly improved because more micronozzles are integrated. The enhanced pumping effect, which is created by rapid bubble collapse processes in the entire main channels, enables a more sustainable liquid supply and hence delays the CHF conditions. Moreover, two-phase flow in terms of pressure drop fluctuations is more stable owing to the effective management of bubble confinement in the entire channel. [ABSTRACT FROM AUTHOR]

In microchannel flow boiling, bubble nucleation, growth and flow regime development are highly influenced by channel cross-section and physical phenomena underlying this flow boiling mechanism are far from being well-established. Relative effects of different forces acting on wall-liquid and liquid–vapor interface of a confined bubble play an important role in heat transfer performances. Therefore, fundamental investigations are necessary to develop enhanced microchannel heat transfer surfaces. Force analysis of nucleating bubble and bubble dynamics in flow boiling silicon nanowire microchannels have been performed based on theoretical, experimental and visualization studies. The relative effects of different forces on flow regimes, instabilities and heat transfer performances of flow boiling in silicon nanowire microchannels have been identified. Inertia, surface tension, shear, buoyancy, and evaporation momentum forces have significant importance at liquid–vapor interface as discussed earlier by other researchers. However, no comparative study has been done for different surface properties till date. Detail analyses of these forces including contact angle effect, channel dimension effect, heat flux effect and mass flux effect in flow boiling microchannels have been conducted in this study. A comparative study between silicon nanowire and plainwall microchannels has been performed based on force analysis in the flow boiling microchannels. Compared to plainwall microchannels, enhanced surface rewetting and CHF are owing to higher surface tension force at liquid–vapor interface and Capillary dominance resulting from silicon nanowires. Whereas, low Weber number in silicon nanowire helps maintaining uniform and stable thin film and improves heat transfer performances. Moreover, results from these studies are compared with the literatures and great agreements have been observed. [ABSTRACT FROM AUTHOR]

A study on bubble growth mechanisms and underlying physical phenomena of flow boiling in silicon nanowire (SiNW) microchannels has been performed and compared these results with plainwall microchannels. A new approach in studying bubble dynamics and forces acting on liquid–vapor (L–V) interface of growing bubble has been proposed based on theoretical, experimental and visual studies. Bubble size, liquid film thickness, interfacial properties are measured and L–V interfaces are detected from high speed visualization data and results are analyzed by vision-based approach. Force analysis during instantaneous bubble growth from bubble nucleation to formation of annular flow regime has been performed for both the SiNW and plainwall microchannel configurations. Results from force analysis show the dominance of surface tension at L–V interface of growing bubble which resulted higher heat transfer contact area, lower thermal resistance and higher thin film evaporation. Whereas, inertia force is dominant at L–V interface of fully grown bubble and it helps in bubble removal process and rewetting before flow reversal. Significant differences between SiNW and plainwall microchannels have been observed in bubble growth mechanism, heat transfer mode and forces acting on L–V interface. [ABSTRACT FROM AUTHOR]

Abstract: In Part II of this study, we report that pressure drop was reduced by approximately 48% and critical heat flux (CHF) was increased by approximately 300% in SiNW microchannels compared to these in smooth wall microchannels. The hydraulic characteristics of the single annular flow were systematically investigated to reveal the mechanisms responsible for the reduced pressure drop and enhanced CHF. In the single annular regime, the liquid and vapor flows were nearly fully separated during the entire flow boiling process (i.e., from the onset of nucleate boiling to the CHF conditions). Moreover, the entrainment droplets were reduced by flattening the profile of the liquid–vapor interfaces using the high capillary pressure generated by SiNWs. These two factors, i.e., flow separation and reduced entrainment droplets, lead to a dramatic reduction of frictional pressure drop. The separation of liquid and vapor flows as well as the improved global and local liquid supply result in a significant CHF enhancement without using inlet restrictors (IR). Reynolds number based the vapor flow at the exit ranged from 0.1 to 2100. [Copyright &y& Elsevier]

Abstract: Flow boiling with deionized water in silicon (Si) microchannels was drastically enhanced in a single annular flow boiling regime enabled by superhydrophilic Si nanowire inner walls. Part I of this study focuses on characterizing enhanced flow boiling heat transfer. Part II focuses on revealing mechanisms in governing pressure drop and critical heat flux (CHF). Compared to flow boiling in plain-wall microchannels without using inlet restrictors (IRs), the average heat transfer coefficient (HTC) and CHF were enhanced by up to 326% and 317% at a mass flux of 389kg/m2 s, respectively. Additionally, compared with flow boiling in microchannels with IRs, HTC of flow boiling in the single annular flow was enhanced by up to 248%; while CHF in the new flow boiling regime was 6.4–25.8% lower. The maximum HTC reached 125.4kW/m2 K at a mass flux of 404kg/m2 s near the exits of microchannels. The significantly promoted nucleate boiling, induced liquid film renewal, and enhanced thin-film evaporation in the self-stabilized and single flow boiling regime are the primary reasons behind the significant heat transfer enhancements during flow boiling. [Copyright &y& Elsevier]