Hierarchically Structured Laser-Induced Graphene for Enhanced Boiling on Flexible Substrates

Aluminum Micropillar Surfaces with Hierarchical Micro- and Nanoscale Features for Enhancement of Boiling Heat Transfer Coefficient and Critical Heat Flux

The rapid progress of electronic devices has necessitated efficient heat dissipation within boiling cooling systems, underscoring the need for improvements in boiling heat transfer coefficient (HTC) and critical heat flux (CHF). While different approaches for micropillar fabrication on copper or silicon substrates have been developed and have shown significant boiling performance improvements, such enhancement approaches on aluminum surfaces are not broadly investigated, despite their industrial applicability. This study introduces a scalable approach to engineering hierarchical micro-nano structures on aluminum surfaces, aiming to simultaneously increase HTC and CHF. One set of samples was produced using a combination of nanosecond laser texturing and chemical etching in hydrochloric acid, while another set underwent an additional laser texturing step. Three distinct micropillar patterns were tested under saturated pool boiling conditions using water at atmospheric pressure. Our findings reveal that microcavities created atop pillars successfully facilitate nucleation and micropillars representing nucleation site areas on a microscale, leading to an enhanced HTC up to 242 kW m-2 K-1. At the same time, the combination of the surrounding hydrophilic porous area enables increased wicking and pillar patterning, defining the vapor-liquid pathways on a macroscale, which leads to an increase in CHF of up to 2609 kW m-2.

Effect of Surface Wettability on Nanoparticle Deposition during Pool Boiling on Laser-Textured Copper Surfaces

Prior studies have evidenced the potential for enhancing boiling heat transfer through modifications of surface or fluid properties. The deployment of nanofluids in pool boiling systems is challenging due to the deposition of nanoparticles on structured surfaces, which may result in performance deterioration. This study addresses the use of TiO2-water nanofluids (mass concentrations of 0.001 wt.% and 0.1 wt.%) in pool boiling heat transfer and concurrent mitigation of nanoparticle deposition on superhydrophobic laser-textured copper surfaces. Samples, modified through nanosecond laser texturing, were subjected to boiling in an as-prepared superhydrophilic (SHPI) state and in a superhydrophobic state (SHPO) following hydrophobization with a self-assembled monolayer of fluorinated silane. The boiling performance assessment involved five consecutive boiling curve runs under saturated conditions at atmospheric pressure. Results on superhydrophilic surfaces reveal that the use of nanofluids always led to a deterioration of the heat transfer coefficient (up to 90%) compared to pure water due to high nanoparticle deposition. The latter was largely mitigated on superhydrophobic surfaces, yet their performance was still inferior to that of the same surface in water. On the other hand, CHF values of 1209 kW m-2 and 1462 kW m-2 were recorded at 0.1 wt.% concentration on both superhydrophobic and superhydrophilic surfaces, respectively, representing a slight enhancement of 16% and 27% compared to the results obtained on their counterparts investigated in water.

Heat Transfer Characteristics of Pool Boiling with Scalable Plasma-Sprayed Aluminum Coatings

To ensure adequate reliability in two-phase cooling systems involving boiling, it is essential to enhance the heat transfer coefficient and maximize the critical heat flux (CHF) limit. A key technique to avoid surface burnout and increase the CHF limit in pool boiling is the frequent coolant supply to the probable dry-out locations. In the present work, we have explored the plasma-spray coating as a surface modification technique for enhancing heat transfer coefficient and CHF value in pool boiling applications. Three plasma-coated aluminum surfaces (C-15, C-20, and C-25) are fabricated on a copper substrate at three different plasma powers of 15, 20, and 25 kW, respectively. Detailed surface morphologies of the plasma-sprayed coatings are presented, and their roles in pool boiling heat transfer mechanisms are analyzed. Plasma-coated surfaces exhibit wickability characteristics and enhanced wettability compared to the plain copper surface. Saturated pool boiling experiments are performed with DI (deionized) water at atmospheric pressure. Plasma spray-coated surfaces show favorable boiling incipience with less wall superheat and more active nucleation sites than the plain copper surface. Compared to the plain copper surface, enhancement values of nearly 68, 60.7, and 55.5% in the heat transfer coefficient are observed for C-15, C-20, and C-25 plasma-coated surfaces, respectively. Experiments could not be performed beyond the heat flux of 197 W/cm² due to repeated failure of the cartridge heaters. Based on the experimental measurement of wickabilities, the CHF values of plasma-coated surfaces have been theoretically calculated. Compared to the plain copper surface, a maximum 2.39 times higher CHF value is observed for C-15 plasma-coated surface. Improved wettability and wickability are responsible for CHF enhancement in the case of plasma-coated surfaces. At higher heat flux, capillary wicking and frequent rewetting of the dryout locations delay the burnout phenomenon, enhancing CHF in plasma-coated surfaces. The plasma-spray coating is a robust and scalable process, which can be a potential candidate for high heat flux dissipation in various industrial applications.

A Graphene Quantum Dot Film with a Nanoengineered Crack-Like Surface via Bubble-Induced Self-Assembly for High-Power Thermal Energy Management Applications

Films with micro/nanostructures that show high wicking performance are promising in water desalination, atmospheric water harvesting, and thermal energy management systems. Here, we use a facile bubble-induced self-assembly method to directly generate films with a nanoengineered crack-like surface on the substrate during bubble growth when self-dispersible graphene quantum dot (GQD) nanofluid is used as the working medium. The crack-like micro/nanostructure, which is generated due to the thermal stress, enables the GQD film to not only have superior capillary wicking performance but also provide many additional nucleation sites. The film demonstrates enhanced phase change-based heat transfer performance, with a simultaneous enhancement of the critical heat flux and heat transfer coefficient up to 169% and 135% over a smooth substrate, respectively. Additionally, the GQD film with high stability enables a performance improvement in the concentration ratio and electrical efficiency of concentrated photovoltaics in an analytical study, which is promising for high-power thermal energy management applications.

Nanosecond Laser-Textured Copper Surfaces Hydrophobized with Self-Assembled Monolayers for Enhanced Pool Boiling Heat Transfer

Increased cooling requirements of many compact systems involving high heat fluxes demand the development of high-performance cooling techniques including immersion cooling utilizing pool boiling. This study presents the functionalization of copper surfaces to create interfaces for enhanced pool boiling heat transfer. Three types of surface structures including a crosshatch pattern, shallow channels and deep channels were developed using nanosecond laser texturing to modify the surface micro- and nanomorphology. Each type of surface structure was tested in the as-prepared superhydrophilic state and superhydrophobic state following hydrophobization, achieved through the application of a nanoscale self-assembled monolayer of a fluorinated silane. Boiling performance evaluation was conducted through three consecutive runs under saturated conditions at atmospheric pressure utilizing water as the coolant. All functionalized surfaces exhibited enhanced boiling heat transfer performance in comparison with an untreated reference. The highest critical heat flux of 1697 kW m^-2 was achieved on the hydrophobized surface with shallow channels. The highest heat transfer coefficient of 291.4 kW m^-2 K^-1 was recorded on the hydrophobized surface with deep channels at CHF incipience, which represents a 775% enhancement over the highest values recorded on the untreated reference. Surface microstructure was identified as the key reason for enhanced heat transfer parameters. Despite large differences in surface wettability, hydrophobized surfaces exhibited comparable (or even higher) CHF values in comparison with their hydrophilic counterparts, which are traditionally considered as more favorable for achieving high CHF values. A significant reduction in bubble departure diameter was observed on the hydrophobized surface with deep channels and is attributed to effective vapor entrapment, which is pointed out as a major contributing reason behind the observed extreme boiling heat transfer performance.

Laser-Induced Graphene-Based Wearable Epidermal Ion-Selective Sensors for Noninvasive Multiplexed Sweat Analysis

Wearable sweat sensors are a rapidly rising research area owing to their convenience for personal healthcare and disease diagnosis in a real-time and noninvasive manner. However, the fast and scalable fabrication of flexible electrodes remains a major challenge. Here, we develop a wearable epidermal sensor for multiplexed sweat analysis based on the laser-induced graphene (LIG) technique. This simple and mask-free technique allows the direct manufacturing of graphene electrode patterns on commercial polyimide foils. The resulting LIG devices can simultaneously monitor the pH, Na⁺, and K⁺ levels in sweat with the sensitivities of 51.5 mV/decade (pH), 45.4 mV/decade (Na⁺), and 43.3 mV/decade (K⁺), respectively. Good reproducibility, stability, and selectivity are also observed. On-body testing of the LIG-based sensor integrated with a flexible printed circuit board during stationary cycling demonstrates its capability for real-time sweat analysis. The concentrations of ions can be remotely and wirelessly transmitted to a custom-developed smartphone application during the period in which the sensor user performs physical activities. Owing to the unique advantages of LIG technique, including facile fabrication, mass production, and versatile, more physiological signals (glucose, uric acid, tyrosine, etc.) could be easily expanded into the LIG-based wearable sensors to reflect the health status or clinical needs of individuals.

Enhancement of Boiling with Scalable Sandblasted Surfaces

Surface engineering has been leveraged by researchers to enhance boiling heat transfer performance, with benefits ranging from improved thermal management to more efficient power generation. While engineered surfaces fabricated using cleanroom processes have shown promising boiling results, scalable methods for surface engineering are still limited despite most real-world industry-scale applications involving large boiling areas. In this work, we investigate the use of sandblasting as a scalable surface engineering technique for the enhancement of pool boiling heat transfer. We vary the size of an abrasive Al₂O₃ sandblasting medium (25, 50, 100, and 150 μm) and quantify its effects on silicon surface conditions and boiling characteristics. The surface morphology and capillary wicking performance are characterized by optical profilometry and capillary rise tests, respectively. Pool boiling results and surface characterization reveal that surface roughness and volumetric wicking rate increase with the abrasive size, which results in improvements in the critical heat flux and the heat transfer coefficient of up to 192.6 and 434.3% compared to a smooth silicon surface, respectively. The significant enhancement achieved with sandblasted surfaces indicates that sandblasting is a promising option for improving boiling performance in industry-scale applications.

Electrothermal Performance of Heaters Based on Laser-Induced Graphene on Aramid Fabric

Nanostructured heaters based on laser-induced graphene (LIG) are promising for heat generation and temperature control in a variety of applications due to their high efficiency as well as a fast, facile, and highly scalable fabrication process. While recent studies have shown that LIG can be written on a wide range of precursors, the reports on LIG-based heaters are mainly limited to polyimide film substrates. Here, we develop and characterize nanostructured heaters by direct writing of laser-induced graphene on nonuniform and structurally porous aramid woven fabric. The synthesis and writing of graphene on aramid fabric is conducted using a 10.6 μm CO2 laser. The quality of laser-induced graphene and electrical properties of the heater fabric is tuned by controlling the lasing process parameters. Produced heaters exhibit good electrothermal efficiency with steady-state temperatures up to 170 °C when subjected to an input power density of 1.5 W cm-2. In addition, the permeable texture of LIG-aramid fabric heaters allows for easy impregnation with thermosetting resins. We demonstrate the encapsulation of fabric heaters with two different types of thermosetting resins to develop both flexible and stiff composites. A flexible heater is produced by the impregnation of LIG-aramid fabric by silicone rubber. While the flexible composite heater exhibits inferior electrothermal performance compared to neat LIG-aramid fabric, it shows consistent electrothermal performance under various electrical and mechanical loading conditions. A multifunctional fiber-reinforced composite panel with integrated de-icing functionality is also manufactured using one ply of LIG-aramid fabric heater as part of the composite layup. The results of de-icing experiments show excellent de-icing capability, where a 5 mm thick piece of ice is completely melted away within 2 min using an input power of 12.8 W.

Influence of Surface Wettability on Bubble Formation and Motion

Bubble dynamics plays an important role in boiling heat transfer, and surface wettability affects bubble behaviors. In the present work, the effects of surface superhydrophilicity (SHI) and superhydrophobicity (SHO) on bubble dynamics are experimentally studied by observing the formation and motion behaviors of air bubbles and vapor bubbles on varied surfaces. For air bubbles to better mimic vapor bubbles, the air bubbles are introduced in a water pool by injecting airflow from a through hole of the surface. Air bubble tests are first conducted on homogeneous SHO and SHI surfaces, respectively. It is observed that surface wettability significantly affects the bubble size and departure frequency. To discover the dynamic behaviors of a bubble under both SHI and SHO, a biphilic surface with SHI and SHO areas is fabricated, and air bubbles are injected right on the biphilic border between the two areas. It is observed the wettability contrast significantly displaces the air bubbles, which spread only onto the SHO area. The biphilic surface is fabricated for the pool boiling test. Vapor bubbles are observed at different stages of the nucleate boiling, showing surface effects similar to the observations of air bubbles. Not only does this study present the influence of surface wettability on air and vapor bubble behaviors but also it provides useful implications for understanding and optimizing the biphilic surface design for enhancing boiling heat transfer.

Nanoparticle-Assisted Pool Boiling Heat Transfer on Micro-Pin-Fin Surfaces

Boiling heat transfer intensification is of significant relevance to energy conversion and various cooling processes. This study aimed to enhance the saturated pool boiling of FC-72 (a dielectric liquid) by surface modifications and explore mechanisms of the enhancement. Specifically, circular and square micro pin fins were fabricated on silicon surfaces by dry etching and then copper nanoparticles were deposited on the micro-pin-fin surfaces by electrostatic deposition. Experimental results indicated that compared with a smooth surface, the micro pin fins increased the heat transfer coefficient and the critical heat flux by more than 200 and 65-83%, respectively, which were further enhanced by the nanoparticles up to 24% and more than 20%, respectively. Correspondingly, the enhancement mechanism was carefully explored by high-speed bubble visualizations, surface wickability measurements, and model analysis. It was quantitatively found that small bubble departure diameters with high bubble departure frequencies promoted high heat transfer coefficients. The wickability, which characterizes the ability of a liquid to rewet a surface, played an important role in determining the critical heat flux, but further analyses indicated that evaporation beneath bubbles was also essential and competition between the wicking and the evaporation finally triggered the critical heat flux.