An experimental investigation of bubble nucleation of a refrigerant in pressurized boiling flows

An experimental investigation is performed to determine the effect of system pressure and heat flux on flow boiling and associated bubble characteristics of a refrigerant in a narrow vertical duct. A high-pressure flow boiling test loop was built and TLC (thermo-chromic liquid crystal) was applied to the back of the heater foil for high resolution and accurate measurement of heater surface temperature. Refrigerant R-134a is used as the test fluid at different pressures ranging from 690 to 827 kPa and different heat fluxes to quantify their influence in bubble characteristics such as bubble nucleation, growth, departure, and coalescence. Two synchronized high resolution and high-speed cameras are used to simultaneously capture TLC images as well as bubbling activities at high frame rates. By varying flow rate and system pressure, TLC and bubble images were captured and analyzed. Results show that the bubble generation frequency and size increase with heat flux. An increase in pressure from 690 to 827 kPa increased the bubble frequency and size by about 32 Hz and 20 μm, respectively. Bubble coalescence was also observed after departure from the nucleation site.     

Pool boiling heat transfer on the microheater surface with and without nanoparticles by pulse heating

We study the pool boiling heat transfer on the microheater surface with and without nanoparticles by pulse heating. Nanofluids are the mixture of de-ionized water and Al₂O₃ particles with 0.1%, 0.2%, 0.5% and 1.0% weight concentrations. The microheater is a platinum surface by 50 × 20 μm. Three types of bubble dynamics were identified. The first type of bubble dynamics is for the boiling in pure water, referring to a sharp microheater temperature increase once a new pulse cycle begins, followed by a continuous temperature increase during the pulse duration stage. Large bubble is observed on the microheater surface and it does not disappear during the pulse off stage. The second type of bubble dynamics is for the nanofluids with 0.1% and 0.2% weight concentrations. The microheater surface temperature has a sharp increase at the start of a new pulse cycle, followed by a slight decrease during the pulse duration stage. Miniature bubble has oscillation movement along the microheater length direction, and it disappears during the pulse off stage. The third type of bubble dynamics occurs at the nanofluid weight concentration of 0.5% and 1.0%. The bubble behavior is similar to that in pure water, but the microheater temperatures are much lower than that in pure water. A structural disjoining pressure causes the smaller contact area between the dry vapor and the heater surface, decreasing the surface tension effect and resulting in the easy departure of miniature bubbles for the 0.1% and 0.2% nanofluid weight concentrations. For the 0.5% weight concentration of nanofluids, coalescence of nanoparticles to form larger particles is responsible for the large bubble formation on the heater surface. The microlayer evaporation heat transfer and the heat transfer mechanisms during the bubble departure process account for the higher heat transfer coefficients for the 0.1% and 0.2% nanofluid weight concentrations. The shortened dry area between the bubble and the heater surface, and the additional thin nanofluid liquid film evaporation heat transfer, account for the higher heat transfer coefficient for the 0.5% nanofluid weight concentration, compared with the pure water runs.     

Time and space resolved wall temperature and heat flux measurements during nucleate boiling with constant heat flux boundary conditions

The lack of time and space resolved measurements under nucleating bubbles has complicated efforts to fully explain pool-boiling phenomena. In this work, time and space resolved temperature and heat flux distributions under nucleating bubbles on a constant heat flux surface were obtained using a 10 × 10 microheater array with 100 μm resolution along with high-speed images. A numerical simulation was used to compute the substrate conduction, which was then subtracted from the heater power to obtain the wall-to-liquid heat transfer. The data indicated that most of the energy required for bubble growth came from the superheated layer around the bubble. Microlayer evaporation and contact line heat transfer accounted for not more than 23% of the total heat transferred from the surface. The dominant heat transfer mechanism was transient conduction into the liquid during bubble departure. Bubble coalescence was not observed to transfer a significant amount of heat.     

CFD Simulation of Boiling Flows Using the Volume-of-Fluid Method within OpenFOAM

This article describes the implementation and validation of a nucleate boiling model in the volume-of-fluid solver of OpenFOAM. Emphasis is put on the implementation of the contact line evaporation, which can typically not be resolved by the numerical grid, and on the conjugate heat transfer between solid and fluid. For validation, the sucking interface problem and the growth of a spherical bubble have been simulated successfully. In order to validate the contact line model and the conjugate heat transfer, the growth of a bubble from a heated steel foil has been calculated.     

Bubble growth and horizontal coalescence in saturated pool boiling on a titanium foil,investigated by high-speed IR thermography

Growth of an isolated bubble and horizontal coalescence events between bubbles of dissimilar size were examined during pool nucleate boiling of water on a horizontal, electrically-heated titanium foil 25 μm thick. Wall temperature measurements on the back of the foil by high-speed IR camera, synchronized with high-speed video camera recordings of the bubble motion, improved the temporal and spatial resolution of previous observations by high-speed liquid crystal thermography to 1 ms and 40 μm, respectively, leading to better detailed maps of the transient distributions of wall heat flux. The observations revealed complex behaviour that disagreed with some other observations and current modelling assumptions for the mechanisms of heat transfer over the wall contact areas of bubbles and interactions between bubbles. Heat transfer occurred from the entire contact area and was not confined to a narrow peripheral triple-contact zone. There was evidence of an asymmetrical interaction between bubbles before coalescence. It was hypothesised that a fast-growing bubble pushed superheated liquid under a slow-growing bubble. Contact of this liquid with regions of the wall that had been pre-cooled during bubble growth caused local reductions in the wall heat flux. During coalescence, movement of liquid under both bubbles caused further changes in the wall heat flux that also depended on pre-cooling. Contraction of the contact area caused a peripheral reduction in the heat flux and there was no evidence of a large increase in heat flux during detachment. Boiling on very thin foils imposes special conditions. Sensitivity to the thermal history of the wall must be taken into account when applying the observations and hypotheses to other conditions.     

Local Heat Flux Investigation During Pool Boiling Single Bubble Cycles Under Reduced Gravity

In the present work the bubble diameter, heater surface temperature distribution, and local heat flux during different stages of single bubble cycles during pool boiling of PF-5060 at a pressure of p = 600 mbar have been investigated in several stable low g levels during the 1st Joint European Partial-g Parabolic Flight (JEPPF) Campaign. In previous parabolic flight campaigns, microgravity conditions were achieved by following a parabolic trajectory with the specially equipped A-300-Zero-G Aircraft. In this recent JEPPF campaign, the parabolic trajectories were slightly shifted, to establish—apart from microgravity conditions—also stable gravity levels of 0.16 g (lunar gravity) and 0.38 g (Martian gravity). High-resolution measurements of the heater surface temperature were performed using high-speed infrared thermography. An infrared (IR)-transparent sputtered heater design was employed in order to allow temperature measurements by IR thermography at a distance of approximately 800 nm to the heater/fluid interface. From the acquired temperature data, the local heat flux distribution was calculated numerically. Bubble shape and interaction were recorded with a high-speed black-and-white camera. In contrast to previous investigations, the stable low gravity levels enabled performance of measurements during single bubble (ebullition) cycles without the influence of residual flows induced by boiling under a different gravity level, as is the case in the beginning of a regular microgravity parabola. The accuracy of the measurement technique could be drastically enhanced compared to earlier publications. A local temperature drop and corresponding heat flux peak have been observed close to the three-phase contact line.     

Coalescence of bubbles in nucleate boiling on microheaters

In this paper, an experiment was performed which is based on a heating surface consisting of microheaters where the temperature of each heater can be individually controlled by an electronic feedback loop. The power consumed by the heaters throughout the cycle of individual bubble growth, coalescence, detachment and departure was measured at high frequencies, thus the heat flux and its variation were obtained. By a careful timing and control of two individual microheaters, we were able to produce two individual bubbles side-by-side. The coalescence would takes place when they grow to a certain size that allows them to touch each other. We have recorded two major heat flux spikes for a typical cycle of boiling with coalescence. The first one corresponds to the nucleation of bubbles; the second one is for the coalescence of the two bubbles. We found that the heat flux variation is closely related to the bubble dynamics and bubble-bubble interaction. By comparing with the single bubble results without coalescence, we also found that the heat transfer is highly enhanced due to the coalescence.     

Fluid flow and heat transfer characteristics of low temperature two-phase micro-channel heat sinks – Part 2. Subcooled boiling pressure drop and heat transfer

This second part of a two-part study explores the performance of a new cooling scheme in which the primary working fluid flowing through a micro-channel heat sink is indirectly cooled by a refrigeration cooling system. The objective of this part of study is to explore the pressure drop and heat transfer characteristics of the heat sink. During single-phase cooling, pressure drop decreased with increasing heat flux because of decreased liquid viscosity. However, pressure drop began increasing with increasing heat flux following bubble departure. These opposite trends produced a minimum in the variation of pressure drop with heat flux. Increasing liquid subcooling decreased two-phase pressure drop because of decreased void fraction caused by strong condensation at bubble interfaces as well as decreased likelihood of bubble coalescence. It is shown macro-channel subcooled boiling pressure drop and heat transfer correlations are unsuitable for micro-channel flows. However, two new modified correlations produced good predictions of the present heat transfer data.     

Nucleate boiling in two types of vertical narrow channels

To explore the mechanism of boiling bubble dynamics in narrow channels, we investigate 2-mm wide I- and Z-shaped channels. The influence of wall contact angle on bubble generation and growth is studied using numerical simulation. The relationships between different channel shapes and the pressure drop are also examined, taking into account the effects of gravity, surface tension, and wall adhesion. The wall contact angle imposes considerable influence over the morphology of bubbles. The smaller the wall contact angle, the rounder the bubbles, and the less time the bubbles take to depart from the wall. Otherwise, the bubbles experience more difficulty in departure. Variations in the contact angle also affect the heat transfer coefficient. The greater the wall contact angle, the larger the bubble-covered area. Therefore, wall thermal resistance increases, bubble nucleation is suppressed, and the heat transfer coefficient is lowered. The role of surface tension in boiling heat transfer is considerably more important than that of gravity in narrow channels. The generation of bubbles dramatically disturbs the boundary layer, and the bubble bottom micro-layer can enhance heat transfer. The heat transfer coefficient of Z-shaped channels is larger than that of the I-shaped type, and the pressure drop of the former is clearly higher.     

Dynamic characteristics of transient boiling on a square platinum microheater under millisecond pulsed heating

A series of experimental investigations of boiling incipience and bubble dynamics of water under pulsed heating conditions for various pulse durations ranging from 1 ms to 100 ms were conducted. Using a very smooth square platinum microheater, 100 μm on a side, and a high-speed digital camera, the boiling incipience was observed and investigated as a function of the bulk temperature of the microheater, pulse power level, and pulse duration. Given a specific pulse duration, for low pulse power levels, there would be no bubble nucleation or bubble mergence, for moderate pulse power levels, individual bubbles generated on the heater merged to form a single large bubble, while for high pulse power levels, the rapid growth of the individual bubbles and subsequent bubble interaction, resulted in a reduction in bubble coalescence into a single larger bubble, referred to as bubble splash. The transient heat flux range at which bubble coalescence occurs was identified experimentally, along with the temporal variations of bubble size, bubble interface velocity and interface acceleration.     

Effects of the liquid polarity and the wall slip on the heat and mass transport characteristics of the micro-scale evaporating transition film

A mathematical model is developed to describe the micro-/nano-scale fluid flow and heat/mass transfer phenomena in an evaporating extended meniscus, focusing on the transition film region under non-isothermal interfacial conditions. The model incorporates polarity contributions to the working fluid field, a slip boundary condition on the solid wall, and thermocapillary stresses at the liquid-vapor interface. Two different disjoining pressure models, one polar and one non-polar, are considered for water as the working fluid so that the effect of polar interactions between the working fluid and solid surface can be exclusively examined on heat and mass transfer from the thin film. The polar effect is examined for the thin film established in a 20-μm diameter capillary pore. The effect of the slip boundary condition is separately examined for the thin film developed in a two-dimensional 20-μm slotted pore. The analytical results show that for a polar liquid, the transition region of the evaporating meniscus is longer than that of a non-polar liquid. In addition, the strong polar attraction with the solid wall acts to lower the evaporative heat transfer flux. The slip boundary condition, on the other hand, increases evaporative heat and mass flux and lowers the liquid pressure gradients and viscous drag at the wall. The slip effect shows a more pronounced enhancement as superheat increases. Another thing to note is that the slip effect of elongating the transition region can counteract the thermocapillary action of reducing the region and a potential delay of thermocapillary driven instability onset may be anticipated.     

Dropwise Condensation Studies on Multiple Scales

Recent advances in nanotechnology, chemical/physical texturing and thin film coating technology generate definite possibilities for sustaining a dropwise mode of condensation for much longer durations than was previously possible. The availability of superior experimental techniques also leads to deeper understanding of the process parameters controlling the relevant transport phenomena, the distinguishing feature of which is the involvement of a hierarchy of length/time scales, proceeding from nuclei formation, to clusters, all the way to macroscopic droplet ensemble, drop coalescence, and subsequent dynamics. This paper is an attempt to connect and present a holistic framework of modeling and studying dropwise condensation at these multiple scales. After a review of the literature, discussions on the following problems are presented: (i) atomistic modeling of nucleation; (ii) droplet–substrate interaction; (iii) surface preparation; (iv) simulation of fluid motion inside sliding drops; (v) experimental determination of the local/ average heat transfer coefficient; and (vi) a macroscopic model of the complete dropwise condensation process underneath horizontal and inclined surfaces. The study indicates that hierarchal modeling is indeed the way forward to capture the complete process dynamics. The microscopic phenomena at the three-phase contact line, leading to the apparent droplet contact angle, influence the shear stress and heat transfer. The nucleation theory captures the quasi-steady-state behavior quite satisfactorily, although the early atomistic nucleation was not seen to have a profound bearing on the steady-state behavior. The latter is strongly governed by the coalescence dynamics. Visual observation of dropwise condensation provides important information for building hierarchical models.     

On the transition from partial to fully developed subcooled flow boiling

The subject of the present study is to relate the boiling heat transfer process with experimentally observed bubble behaviour during subcooled flow boiling of water in a vertical heated annulus. It presents an attempt to explain the transition from partial to fully developed flow boiling with regard to bubble growth rates and to the time that individual bubbles spend attached to the heater surface.Within the partial nucleate boiling region bubbles barely change in size and shape while sliding a long distance on the heater surface. Such behaviour indicates an important contribution of the microlayer evaporation mechanism in the overall heat transfer rate. With increasing heat flux, or reducing flow rate at constant heat flux, bubble growth rates increase significantly. Bubbles grow while sliding, detach from the heater, and subsequently collapse in the bulk fluid within a distance of 1-2 diameters parallel to the heater surface. This confirms that bubble agitation becomes a leading heat transfer mode with increasing heat flux. There is however, a sharp transition between the two observed bubble behaviours that can be taken as the transition from partial to fully developed boiling. Hence, this information is used to develop a new model for the transition from partial to fully developed subcooled flow boiling.     

Nanofluid stabilizes and enhances convective boiling heat transfer in a single microchannel

The flow boiling heat transfer in a single microchannel was investigated with pure water and nanofluid as the working fluids. The microchannel had a size of 7500 × 100 × 250 μm, which was formed by two pyrex glasses and a silicon wafer. A platinum film with a length of 3500 μm and a width of 80 μm was deposited at the bottom channel surface, acting as the heater and temperature sensor. The nanofluid had a low weight concentration of 0.2%, consisting of de-ionized water and 40 nm Al₂O₃ nanoparticles. The nanoparticle deposition phenomenon was not observed. The boiling flow displays chaotic behavior due to the random bubble coalescence and breakup in the milliseconds timescale at moderate heat fluxes for pure water. The flow instability with large oscillation amplitudes and long cycle periods was observed with further increases in heat fluxes. The flow patterns are switched between the elongated bubbles and isolated miniature bubbles in the timescale of 100 s. It is found that nanofluid significantly mitigate the flow instability without nanoparticle deposition effect. The boiling flow is always stable or quasi-stable with significantly reduced pressure drop and enhanced heat transfer. Miniature bubbles are the major flow pattern in the microchannel. Elongated bubbles temporarily appear in the milliseconds timescale but isolated miniature bubbles will occupy the channel shortly. The decreased surface tension force acting on the bubble accounts for the smaller bubble size before the bubble departure. The inhibition of the dry patch development by the structural disjoining pressure, and the enlarged percentage of liquid film evaporation heat transfer region with nanoparticles, may account for the heat transfer enhancement compared to pure water.     

Direct simulation of spray cooling: Effect of vapor bubble growth and liquid droplet impact on heat transfer

Numerical modeling of multiphase flow using level set method is discussed. The 2-D model considers the effect of surface tension between liquid and vapor, gravity, phase change and viscosity. The level set method is used to capture the movement of the free surface. The detail of incorporating the mechanism of phase change in the incompressible Navier–Stokes equations using the level set method is described. The governing equations are solved using the finite difference method. The computer model is used to study the spray cooling phenomenon in the micro environment of about 40 μm thick liquid layer with vapor bubble growing due to nucleation. The importance of studying the heat transfer mechanism in thin liquid film for spray cooling is identified. The flow and heat transfer details are presented for two cases: (1) when the vapor bubble grows due to nucleation and (2) merges with the vapor layer above the liquid layer and when a liquid droplet impacts the thin liquid layer with vapor bubble growing.     

Interfacial temperature measurements,high-speed visualization and finite-element simulations of droplet impact and evaporation on a solid surface

The objective of this work is to investigate the coupling of fluid dynamics, heat transfer and mass transfer during the impact and evaporation of droplets on a heated solid substrate. A laser-based thermoreflectance method is used to measure the temperature at the solid–liquid interface, with a time and space resolution of 100 μs and 20 μm, respectively. Isopropanol droplets with micro- and nanoliter volumes are considered. A finite-element model is used to simulate the transient fluid dynamics and heat transfer during the droplet deposition process, considering the dynamics of wetting as well as Laplace and Marangoni stresses on the liquid–gas boundary. For cases involving evaporation, the diffusion of vapor in the atmosphere is solved numerically, providing an exact boundary condition for the evaporative flux at the droplet–air interface. High-speed visualizations are performed to provide matching parameters for the wetting model used in the simulations. Numerical and experimental results are compared for the transient heat transfer and the fluid dynamics involved during the droplet deposition. Our results describe and explain temperature oscillations at the drop–substrate interface during the early stages of impact. For the first time, a full simulation of the impact and subsequent evaporation of a drop on a heated surface is performed, and excellent agreement is found with the experimental results. Our results also shed light on the influence of wetting on the heat transfer during evaporation.     

Interfacial heat transfer during subcooled flow boiling

In order to develop a mechanistic model for the subcooled flow boiling process, the key issues which must be addressed are wall heat flux partitioning and interfacial (condensation) heat transfer. The sink term in the two-fluid models for void fraction prediction is provided by the condensation rate at the vapor-liquid interface. Low pressure subcooled flow boiling experiments, using water, were performed using a vertical flat plate heater to investigate the bubble collapse process. A high-speed CCD camera was used to record the bubble collapse in the bulk subcooled liquid. Based on the analyses of these digitized images, bubble collapse rates and the associated heat transfer rate were determined. The experimental data were in turn used to correlate the bubble collapse rate and the interfacial heat transfer rate. These correlations are functions of bubble Reynolds number, liquid Prandtl number, Jacob number, and Fourier number. The correlations account for both the effect of forced convection heat transfer and thickening of the thermal boundary layer as the vapor bubble condenses which in turn makes the condensation heat transfer time dependent. Comparison of the measured experimental data with those predicted from the correlations show that predictions are well within ±25% of the experimentally measured values. These correlations have also been compared with those available in the literature.     

OPTICAL MEASUREMENT OF MICROSCALE TRANSPORT PROCESSES IN DROPWISE CONDENSATION

The optimum use of interfacial free-energy gradients to control fluid flow in small regions naturally leads to simpler passive heat transfer systems. In this context, "passive" refers to the natural pressure field for fluid flow due to changes in the intermolecular force field resulting from an imposed nonisothermal temperature field. Although the particular constrained vapor bubble (CVB) discussed can be viewed as a large version of a wickless heat pipe, it is a much more general heat transfer concept. Herein, it is an ideal system for the optical study of microscale transport processes in droplet condensation due to interfacial phenomena. This article concerns the movement of a single condensed ethanol sessile drop into a concave liquid film. The intermolecular force is found to be much larger than the gravitational force and dominates condensate removal. A dimensionless force balance for viscous shear stress demonstrates the effect of changes in the contact angle and curvature. A dimensionless difference in free energy is identified as the cause of spontaneous condensate removal.     

Numerical investigation of subcooled flow boiling in segmented finned microchannels

Bubble growth behavior and heat transfer characteristics during subcooled flow boiling in segmented finned microchannels have been numerically investigated. Simulations have been performed for a single row of segmented finned microchannel and predicted results are compared with experimental investigations. Onset of nucleation, formation of bubbles, their growth and movements have been investigated for different values of applied heat flux. Mechanism of bubble expansion without clogging resulting in enhanced heat transfer in segmented finned microchannels has been explained. Temperature and pressure fluctuations during subcooled flow boiling condition have been investigated. It is observed that at high heat flux, thin liquid film trapped between the bubble and channel wall is evaporated leading to localized heating effect. Predicted flow patterns are similar to experimental results. However, simulations over predict the bubble growth rate and heat transfer coefficient.     

A Photographic study of subcooled flow boiling burnout at high heat flux and velocity

The present paper reports the results of a visualization study of the burnout in subcooled flow boiling of water, with square cross section annular geometry (formed by a central heater rod contained in a duct characterized by a square cross section). The coolant velocity is in the range 3–10 m/s. High speed movies of flow pattern in subcooled flow boiling of water from the onset of nucleate boiling up to physical burnout of the heater are recorded. From video images (single frames taken with a stroboscope light and an exposure time of 1 μs), the following general behaviour of vapour bubbles was observed: when the rate of bubble generation is increasing, with bubbles growing in the superheated layer close to the heating wall, their coalescence produces a type of elongated bubble called vapour blanket. One of the main features of the vapour blanket is that it is rooted to the nucleation site on the heated surface. Bubble dimensions are given as a function of thermal-hydraulic tested conditions for the whole range of velocity until the burnout region. A qualitative analysis of the behaviour of four stainless steel heater wires with different macroscopic surface finishes is also presented, showing the importance of this parameter on the dynamics of the bubbles and on the critical heat flux.