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Updated: Aug 1, 2025
07:32
Pool-Boiling Heat-Transfer Enhancement on Cylindrical Surfaces with Hybrid Wettable Patterns
Published on: April 10, 2017
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Heat Transfer Characteristics of Pool Boiling with Scalable Plasma-Sprayed Aluminum Coatings
Atul Ranjan1, Akash Priy1, Israr Ahmad1
1Sustainable Energy Research Laboratory, Department of Mechanical Engineering, Indian Institute of Technology Patna, Patna 801106, India.
Langmuir : the ACS Journal of Surfaces and Colloids
|April 24, 2023
Summary
Plasma spray coating enhances heat transfer and critical heat flux (CHF) in boiling systems. This surface modification improves coolant supply to dry-out locations, significantly boosting reliability for high heat flux dissipation.
Area of Science:
- Materials Science and Engineering
- Thermal Engineering
- Surface Science
Background:
- Reliability in two-phase cooling systems requires enhanced heat transfer coefficients and maximized critical heat flux (CHF) limits.
- Surface modifications are crucial for improving heat transfer and preventing burnout in pool boiling applications.
- Plasma-spray coating is explored as a novel surface engineering technique.
Purpose of the Study:
- To investigate the effectiveness of plasma-spray coating in enhancing heat transfer coefficient and CHF in pool boiling.
- To analyze the surface morphology and its correlation with boiling heat transfer mechanisms.
- To evaluate the potential of plasma-coated surfaces for high heat flux dissipation.
Main Methods:
- Fabrication of three aluminum surfaces (C-15, C-20, C-25) on a copper substrate using plasma-spray coating at varying power levels (15, 20, 25 kW).
- Characterization of surface morphologies of the plasma-sprayed coatings.
- Saturated pool boiling experiments using deionized water at atmospheric pressure to measure heat transfer performance and boiling incipience.
Main Results:
- Plasma-coated surfaces exhibited improved wettability and wickability compared to a plain copper surface.
- Significant enhancements in heat transfer coefficient were observed: ~68% for C-15, ~60.7% for C-20, and ~55.5% for C-25.
- A maximum theoretical CHF enhancement of 2.39 times was calculated for the C-15 surface, attributed to capillary wicking and rewetting.
Conclusions:
- Plasma-spray coating is a viable technique for enhancing pool boiling heat transfer and CHF.
- Improved wettability and wickability of plasma-coated surfaces are key factors for superior thermal performance.
- The robust and scalable nature of plasma-spray coating makes it suitable for industrial high heat flux applications.
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