Adiabatic nitrogen-water two-phase flow across a bank of staggered circular micropillars, 100μm long with a diameter of 100μm and a pitch-to-diameter ratio of 1.5, was investigated experimentally for Reynolds number ranging from 5 to 50. Flow patterns, void fraction, and pressure drop were obtained, discussed, and compared to large scale as well as microchannel results. Two-phase flow patterns were determined by flow visualization, and a flow map was constructed as a function of gas and liquid superficial velocities. Significant deviations from conventional scale systems, with respect to flow patterns and trend lines, were observed. A unique flow pattern, driven by surface tension, was observed and termed bridge flow. The applicability of conventional scale models to predict the void fraction and two-phase frictional pressure drop was also assessed. Comparison with a conventional scale void fraction model revealed good agreement, but was found to be in a physically wrong form. Thus, a modified physically based model for void fraction was developed. A two-phase frictional multiplier was found to be a strong function of mass flux, unlike in previous microchannel studies. It was observed that models from conventional scale systems did not adequately predict the two-phase frictional multiplier at the microscale, thus, a modified model accounting for mass flux was developed.

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Flow boiling of 1-methoxyheptafluoropropane (HFE 7000) in 222 μm hydraulic diameter channels containing a single row of 24 inline 100 μm pin fins was studied for mass fluxes from 350 kg/m2 s to 827 kg/m2 s and wall heat fluxes from 10 W/cm2 to 110 W/cm2. Flow visualization revealed the existence of isolated bubbles, bubbles interacting, multiple flow, and annular flow. The observed flow patterns were mapped as a function of the boiling number and the normalized axial distance. The local heat transfer coefficient during subcooled boiling was measured and found to be considerably higher than the corresponding single-phase flow. Furthermore, a thermal performance evaluation comparison with a plain microchannel revealed that the presence of pin fins considerably enhanced the heat transfer coefficient.

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Flow boiling of HFE 7000 in five parallel microchannels of 222 μm hydraulic diameter, each containing a single row of 24 in-line 100 μm pin fins, was investigated. High speed photography revealed the dominant flow patterns, namely, the bubbly flow, the multiple flow, and the wavy-annular flow. The interaction of the bubble with the pin fins during nucleate boiling from G=350 kg/m2 s to G=827 kg/m2 s and wall heat fluxes from 10 W/cm2 to 110 W/cm2 is detailed.

Size scale effect of adiabatic two-phase cross-flow over micropillars was experimentally investigated, and the mechanisms controlling the formation and transition of the recently discovered bridge flow was examined. A transition criterion, based on the Weber and Euler numbers, for the breakage of the bridges, is provided. The bridges break from the surface when the product of the Weber and Euler numbers is larger than ϳ1; otherwise, the bridges cease to exist by coalescing with liquid slugs.

Flow boiling of HFE 7000 on micro pin fins entrenched inside microchannels was experimentally studied for G = 350 kg/m2s to G = 827 kg/m2s and wall heat fluxes from 10 W/cm2 to 110 W/cm2. Bubbly, multiple, and wavy-annular flow patterns were observed. The interaction of the bubble with the pin fins during nucleate boiling is detailed.