Microstructured uniformly and non-uniformly wettable surfaces were created on 25-m-thin stainless steel foils by laser texturing using a marking nanosecond Nd:YAG laser ( = 1064 nm) and utilizing various laser fluences and scan line separations. High-speed photography and high-speed IR thermography were used to investigate nucleate boiling heat transfer on the microstructured surfaces. The most pronounced results were obtained on a surface with nonuniform microstructure and non-uniform wettability. The obtained results show up to a 110 % higher heat transfer coefficients and 20-40 times higher nucleation site densities compared to the untextured surface. We show that the number of active nucleation sites is significantly increased in the vicinity of microcavities that appeared in areas with the smallest (10 m) scan line separation. Furthermore, this confirms the predictions of nucleation criteria and proves that straightforward, cost-effective nanosecond laser texturing allows the production of cavities with diameters of up to a few micrometers and surfaces with non-uniform wettability. Additionally, this opens up important possibilities for a more deterministic control over the complex boiling process.

This study presents the application of hydrophobic polydimethylsiloxane-silica coating used for the development of biphilic surfaces that are designed to enhance the heat transfer during boiling. Surface analyses showed that this coating exhibits a high hydrophobicity due to its hierarchical structure and the use of hydrophobic polymer. An appropriate thermal treatment leads to the oxidation of the methyl groups and a formation of silicon oxide and silicon carbide that result in a wettability transition from hydrophobic to superhydrophilic. On this basis, we manufactured hydrophobic/superhydrophilic patterns on stainless-steel foils using a pulsed Nd:YAG laser. The uniform, superhydrophilic surface exhibited a 350% larger critical heat flux (CHF) than bare stainless-steel foil. High-speed IR thermography revealed that the increased wettability reduced the bubble contact diameter, allowed a higher density of active nucleation sites, and delayed the dry-out. The biphilic surfaces with differently sized hydrophobic spots exhibited the highest heat transfer coefficients, with an up to 200% higher CHF compared to the bare stainless steel. Smaller hydrophobic spots reduced the bubble diameter and increased the nucleation frequency. However, surfaces with larger hydrophobic regions promoted boiling incipience and exhibited higher heat transfer coefficients at low heat fluxes. These results suggest that the optimal biphilic pattern could only be determined for a particular operating point. Our data provide a new insight into the complex phenomena of nucleate pool boiling on chemically and mechanically heterogeneous surfaces.

Nucleate boiling enables effective cooling and heat transfer at low temperature differences between a heated surface and the surrounding fluid. It is utilized in many applications, ranging from large power plants to small microelectronics. To enhance the boiling process by minimization of the surface temperature and increase the maximum attainable heat flux, several approaches for surface modifications were recently developed. However, each of them has at least one important drawback, including challenging and expensive production, mechanical and/or thermal instability or problematic scale-up. Herein, a straightforward, robust and flexible method using a nanosecond fiber laser for production of surfaces with multi-scale micro-cavities (with diameters ranging from 0.2 to 10 μm) is developed. Examination of these surfaces in two very contrasting fluids - water, which is polar, has high surface tension and high latent heat of vaporization; and non-polar, dielectric tetradecafluorohexane (FC-72) with low surface tension and much lower latent heat - confirms that such surfaces enable enhanced heat transfer and controlled boiling in combination with diverse fluids. This demonstration suggests that the developed method has the potential to overcome the current limitations for further miniaturization of microelectronic devices and to increase performance and safety in high heat flux systems.

Functionalized interfaces enhancing phase-change processes have immense applicability in thermal management. Here, a methodology for fabrication of surfaces enabling extreme boiling heat transfer performance is demonstrated, combining direct nanosecond laser texturing and chemical vapor deposition of a hydrophobic fluorinated silane. Multiple strategies of laser texturing are explored on aluminum with subsequent nanoscale hydrophobization. Both superhydrophilic and superhydrophobic surfaces with laser-engineered microcavities exhibit significant enhancement of the pool boiling heat transfer. Surfaces with superhydrophobic microcavities allow for enhancements of a heat transfer coefficient of over 500%. Larger microcavities with a mean diameter of 4.2 μm, achieved using equidistant laser scanning separation, induce an early transition into the favorable nucleate boiling regime, while smaller microcavities with a mean diameter of 2.8 μm, achieved using variable separation, provide superior performance at high heat fluxes. The enhanced boiling performance confirms that the Wenzel wetting regime is possible during boiling on apparently superhydrophobic surfaces. A notable critical heat flux enhancement is demonstrated on superhydrophobic surfaces with an engineered microstructure showing definitively the importance and concomitant effect of both the surface wettability and topography for enhanced boiling. The fast, low-cost, and repeatable fabrication process has great potential for advanced thermal management applications.

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