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NASA NTRS2002

A Comparative Study of Three Methodologies for Modeling Dynamic Stall

During the past two decades, there has been an increased reliance on the use of computational fluid dynamics methods for modeling rotors in high speed forward flight. Computational methods are being developed for modeling the shock induced loads on the advancing side, first-principles based modeling of the trailing wake evolution, and for retreating blade stall. The retreating blade dynamic stall problem has received particular attention, because the large variations in lift and pitching moments encountered in dynamic stall can lead to blade vibrations and pitch link fatigue. Restricting to aerodynamics, the numerical prediction of dynamic stall is still a complex and challenging CFD problem, that, even in two dimensions at low speed, gathers the major difficulties of aerodynamics, such as the grid resolution requirements for the viscous phenomena at leading-edge bubbles or in mixing-layers, the bias of the numerical viscosity, and the major difficulties of the physical modeling, such as the turbulence models, the transition models, whose both determinant influences, already present in static maximal-lift or stall computations, are emphasized by the dynamic aspect of the phenomena.

Sankar, L.↗

DOE OSTI2022

Effects of variable deceleration periods on Rayleigh-Taylor instability with acceleration reversals

The dynamics of an interfacial flow that is initially Rayleigh-Taylor unstable but becomes statically stable for some intermediate period due to the reversal of the externally imposed acceleration field is studied. We discuss scenarios that consider both single and double-acceleration reversals. The accel-decel (AD) case consists of a single reversal imposed at an instant after the constant acceleration instability has entered a self-similar regime. The layer of mixed fluid ceases to grow upon acceleration reversal, and the dominant mechanics are due to internal wave oscillations. Variation of mass flux and the Reynolds stress anisotropy is observed due to the action of the internal waves. Here, a second reversal of the AD case that is termed as accel-decel-accel, ADA is then explored; the response of the mixing layer is shown to depend strongly on the duration and the periodicity of the Reynolds stress anisotropy of the mixing layer during the deceleration period. We explore the effect of this variable deceleration period after the second acceleration reversal where the flow once again becomes Rayleigh-Taylor unstable based on metrics that include the integral mixing-layer width, bubble and spike amplitudes, mass flux, Reynolds stress anisotropy tensor, and the molecular mixing parameter.

42 ENGINEERING↗

NASA NTRS2005

R and D work on the constrained vapor bubble system for a microgravity experiment

We are working with Project Scientists R. Balasubramanian and Sang Young Son, and a NASA Projects Team headed by Sue Motil at the Glenn Research Center on the design and development of an experimental system for use on the International Space Station during the year 2006. John Eustace is the coordinator for the flight experiment at Zin-Tech (previously Northrop-Grumman) for the design and development of the Constrained Vapor Bubble Heat Exchanger, CVBHX, cell which will fit into the Light Microscope Module, LMM. Good progress is being made. The CDR for the LMM being developed was held on December 10-1 1,2003. Experimental results obtained under microgravity conditions will be compared with those obtained at Rensselaer. Basic and applied research at Rensselaer continues on the experimental and theoretical details associated with passive phase change heat transfer processes controlled by interfacial forces in the CVBHX. The extensive results of our current research are presented in the 23 external publications listed below. Twenty-two external presentations have been given. Briefly, evaporation/condensation data from both vertical and horizontal CVBHX systems were obtained and analyzed for both polar (wetting) and apolar (partially wetting) fluids. The vertical system is axi-symmetric, but strongly effected by gravity. Whereas, the horizontal system is asymmetric, but weakly effected by gravity. Therefore, there will be significant differences in the operation of the cell in the earth s environment versus the operation under microgravity conditions. Due to its relative large size, the system s performance should be optimum under micro-gravity conditions, where the CVBHX should be a very effective passive heat exchanger. The CVBHX was found to be an ideal experimental setup in which to study the effects of interfacial phenomena on both the evaporation and drop-wise condensation processes. The optical technique (Image Analyzing Interferometry, IAI), which is based on the measurement and analysis of the reflectivity pattern of a thin film, was significantly improved. The accuracy of the IAI system is of critical importance to the success of the mission because it is used to measure the details of the pressure field in the liquid by measuring the film thickness profile. The accuracy was found to be excellent and various publications/presentations documenting these new results were written. Significant new results were also obtained for the effect of the oscillating contact line region on evaporation. Three doctoral students graduated under this grant. All three work in US industry, two for Intel. Another doctoral student is in his third year of study and will finish under an extension of the NASA grant: # NNC05GA27G.

Wayner, P. C., Jr.↗

NASA NTRS2015

Numerical Modeling of the Transient Chilldown Process of a Cryogenic Propellant Transfer Line

Before cryogenic fuel depots can be fully realized, efficient methods with which to chill down the spacecraft transfer line and receiver tank are required. This paper presents numerical modeling of the chilldown of a liquid hydrogen tank-to-tank propellant transfer line using the Generalized Fluid System Simulation Program (GFSSP). To compare with data from recently concluded turbulent LH2 chill down experiments, seven different cases were run across a range of inlet liquid temperatures and mass flow rates. Both trickle and pulse chill down methods were simulated. The GFSSP model qualitatively matches external skin mounted temperature readings, but large differences are shown between measured and predicted internal stream temperatures. Discrepancies are attributed to the simplified model correlation used to compute two-phase flow boiling heat transfer. Flow visualization from testing shows that the initial bottoming out of skin mounted sensors corresponds to annular flow, but that considerable time is required for the stream sensor to achieve steady state as the system moves through annular, churn, and bubbly flow. The GFSSP model does adequately well in tracking trends in the data but further work is needed to refine the two-phase flow modeling to better match observed test data.

Chilldown↗

NASA NTRS2023

Cryogenic Flow Boiling in Microgravity: Effects of Reduced Gravity on Two-Phase Fluid Physics and Heat Transfer

With the growing interest in space exploration, cryogenic technologies involving two-phase flow and heat transfer are in high demand to successfully procure advanced space applications such as fuel depots and nuclear thermal propulsion (NTP) systems for deep space missions. However, the unique and extreme thermal properties of cryogenic fluids introduce distinct flow boiling fluid physics and energy transport phenomena, which differ significantly from those observed with conventional fluids. Understanding the unique two-phase physics in cryogenic flow boiling remains an ongoing challenge. Furthermore, the lack of readily available microgravity cryogenic steady-state heat transfer data hinders the assessment of gravitational effects on cryogenic flow boiling. This study aims to elucidate the gravitational effects on two-phase fluid physics and heat transfer by conducting the first-ever experimental measurement of cryogenic flow boiling performance using a steady-state heated method in a reduced gravity environment. Parabolic flight experiments were performed to acquire both heat transfer measurements and high-speed video of interfacial behaviors, under varying gravity levels (microgravity, hypergravity, Lunar gravity, and Martian gravity). The experiments involved flow boiling of liquid nitrogen (LN 2 ) with a near-saturated inlet along a circular heated tube of dimensions 8.5-mm inner diameter and 680-mm heated length. The operating parameters varied are mass velocity of 398.3 - 1342.8 kg/m2s, inlet quality of -0.08 to -0.01, and inlet pressure of 413.68 - 689.48 kPa. Captured microgravity flow patterns range from bubbly to annular, all having vapor structures that are larger than those under higher gravity levels. Under microgravity, absence of buoyancy yields symmetrical vapor structures without flow stratification, laying a physical foundation for the distinct two-phase heat transfer trends during LN 2 flow boiling in microgravity. Transient data collected during the flight parabolas exhibited decreasing heated wall temperature as the aircraft transitioned from hypergravity to microgravity phases. The temperature variation indicated an enhancement in flow boiling heat transfer with decreasing gravity levels and a reduction with increasing gravity levels. The effect of reduced gravity on cryogenic flow boiling heat transfer coefficient (HTC) is discussed based on steady state heat transfer analysis. Seminal HTC correlations are evaluated against the measured microgravity HTC data, of which one is identified for superior accuracy in predicting microgravity data. Finally, a new HTC correlation is proposed to improve accuracy of microgravity predictions, yet there still exists room for further improvement with future terrestrial flow boiling experiments at different flow orientations relative to Earth gravity.

Microgravity↗

DOE OSTI2025

A Comparison of GPU-Accelerated Multiphase CFD Solvers on the Polaris Supercomputer: Part 1

This report is in support of the Innovative and Novel Computational Impact on Theory and Experiment (INCITE) program sponsored by the U.S. Department of Energy (USDOE). With INCITE-level resources, one project, titled BubblyFlow, was granted computational resources for the 2025 calendar year on the Polaris supercomputer at the Argonne Leadership Computing Facility (ALCF). The project aims to conduct simulations to understand the fundamental characteristics of turbulent bubbly flow phenomena in nature. Staff at the ALCF and Argonne’s Computational Science division, along with collaborators at the City College of New York and University of Illinois at Chicago, helped a summer student to assess the accuracy and performance of two high performance computing (HPC) codes. Both codes, ImExLBM and FluTAS, are fundamentally different in their mathematical and numerical modeling. However, both may be used to solve the same physical problem. The collaboration sought to better understand the differences between both codes in terms of accuracy and efficiency. This would ultimately help the BubblyFlow project better utilize resources and establish a knowledge-base of code capabilities in future simulation campaigns. We compare ImExLBM and FluTAS, two high-performance multiphase computational fluid dynamics (CFD) solvers, in terms of physical fidelity, time-to-solution, and parallel efficiency. We validate ImExLBM (Implicit-Explicit Lattice Boltzmann Method) against a canonical benchmark and assess it’s performance relative to FluTAS (Fluid Transport Accelerated Solver), a well-established open-source CFD code.

97 MATHEMATICS AND COMPUTING↗

NASA NTRS1985

Contact angle and surface tension measurements of a five-ring polyphenyl ether

Contact angle measurements were performed for a five-ring polyphenyl ether isomeric mixture on M-50 steel in a dry nitrogen atmosphere. Two different techniques were used: (1) a tilting plate apparatus, and (2) a sessile drop apparatus. Measurements were made for the temperature range 25 to 190 C. Surface tension was measured by a differential maximum bubble pressure technique over the range 23 to 220C in room air. The critical surface energy of spreading (gamma (sub c)) was determined for the polyphenyl ether by plotting the cosine of the contact angle (theta) versus the surface tension (gamma (sub LV)). The straight line intercept at cosine theta = 1 is defined as gamma (sub c). Gamma (sub c) was found to be 30.1 dyn/cm for the tilting plate technique and 31.3 dyn/cm for the sessile drop technique. These results indicate that the polyphenyl ether is inherently autophobic (i.e., it will not spread on its own surface film until its surface tension is less than gamma (sub c). This phenomenon is discussed in light of the wettability and wear problems encountered with this fluid.

Jones, W. R., Jr.↗

NASA NTRS2004

Theoretical and Experimental Investigation of the Stability of an Evaporating Constrained Vapor Bubble

The major accomplishments of the experimental portion of the research were documented in Ling Zheng's doctoral dissertation. Using Pentane, he obtained a considerable amount of data on the stability and heat transfer characteristics of an evaporating meniscus. The important points are that experimental equipment to obtain data on the stability and heat transfer characteristics of an evaporating meniscus were built and successfully operated. The data and subsequent analyses were accepted by the Journal of Heat Transfer for publication in 2004 [PU4]. The work was continued by a new graduate student using HFE-7000 [PU3] and then Pentane at lower heat fluxes. The Pentane results are being analyzed for publication. The experimental techniques are currently being used in our other NASA Grant. The oscillation of the contact line observed in the experiments involves evaporation (retraction part) and spreading. Since both processes occur with finite contact angles, it is important to derive a precise equation of the intermolecular forces (disjoining pressure) valid for non-zero contact angles. This theoretical derivation was accepted for publication by Journal of Fluid Mechanics [PU5]. The evaporation process near the contact line is complicated, and an idealized micro heat pipe has been proposed to help in elucidating the detailed evaporation process [manuscripts in preparation].

Wayner, P. C., Jr.↗

NASA NTRS1986

Contact angle and surface tension measurements of a five-ring polyphenyl ether

Contact angle measurements were performed for a five-ring polyphenyl ether isomeric mixture on M-50 steel in a dry nitrogen atmosphere. Two different techniques were used: (1) a tilting plate apparatus, and (2) a sessile drop apparatus. Measurements were made for the temperature range 25 to 190 C. Surface tension was measured by a differential maximum bubble pressure technique over the range 23 to 220 C in room air. The critical surface energy of spreading (gamma /sub c/) was determined for the polyphenyl ether by plotting the cosine of the contact angle (theta) versus the surface tension (gamma /sub LV/). The straight line intercept at cosine theta = 1 is defined as gamma (sub c). Gamma (sub c) was found to be 30.1 dyn/cm for the tilting plate technique and 31.3 dyn/cm for the sessile drop technique. These results indicate that the polyphenyl ether is inherently autophobic (i.e., it will not spread on its own surface film until its surface tension is less than gamma /sub c/). This phenomenon is discussed in light of the wettability and wear problems encountered with this fluid.

Jones, W. R., Jr.↗

NASA NTRS2000

Nucleate Boiling Heat Transfer Studied Under Reduced-Gravity Conditions

Boiling is known to be a very efficient mode of heat transfer, and as such, it is employed in component cooling and in various energy-conversion systems. In space, boiling heat transfer may be used in thermal management, fluid handling and control, power systems, and on-orbit storage and supply systems for cryogenic propellants and life-support fluids. Recent interest in the exploration of Mars and other planets and in the concept of in situ resource utilization on the Martian and Lunar surfaces highlights the need to understand how gravity levels varying from the Earth's gravity to microgravity (1g = or > g/g(sub e) = or > 10(exp -6)g) affect boiling heat transfer. Because of the complex nature of the boiling process, no generalized prediction or procedure has been developed to describe the boiling heat transfer coefficient, particularly at reduced gravity levels. Recently, Professor Vijay K. Dhir of the University of California at Los Angeles proposed a novel building-block approach to investigate the boiling phenomena in low-gravity to microgravity environments. This approach experimentally investigates the complete process of bubble inception, growth, and departure for single bubbles formed at a well-defined and controllable nucleation site. Principal investigator Professor Vijay K. Dhir, with support from researchers from the NASA Glenn Research Center at Lewis Field, is performing a series of pool boiling experiments in the low-gravity environments of the KC 135 microgravity aircraft s parabolic flight to investigate the inception, growth, departure, and merger of bubbles from single- and multiple-nucleation sites as a function of the wall superheat and the liquid subcooling. Silicon wafers with single and multiple cavities of known characteristics are being used as test surfaces. Water and PF5060 (an inert liquid) were chosen as test liquids so that the role of surface wettability and the magnitude of the effect of interfacial tension on boiling in reduced gravity can be investigated.

Chao, David F.↗

NASA NTRS2024

The CapiSorb Visible System (CVS) Demonstrations on ISS

Falling liquid film amine sorbent reactors have been successfully employed to scrub CO 2 aboard submarines for decades. However, applying such proven methods aboard orbiting and coast spacecraft is significantly challenged by the nearly weightless environment, where liquid sprays and films do not fall, and vapor bubbles and gases do not rise. The Capillary Sorbent (CapiSorb) Visible System (CVS) is a technology demonstration experiment performed aboard the ISS April 18 – 21, 2023. The system establishes stable steady thin liquid film flows in Contactor (absorber) and Degasser (desorber/stripper) replacing the passive role of gravity with the combined passive roles of surface tension, wetting, and system geometry. A TOX-0 fructose ersatz liquid sorbent is employed enabling ‘transparent’ experiments performed and filmed by the crew safely in the open cabin of the ISS. Completed objectives include demonstrations of stable passive ‘massively’ parallel planar thin film capillary flows across atmospheric pressure Contactor and sealed heated Degasser. The impacts of varying flow rate, flow direction, heat input, viscosity, positive and negative Degasser pressures, condensate collection and return, fluid distribution, interfacial stability, and others are reported. At least 49 diagnostics are recorded for digitization and subsequent thermal-fluids model validation by a single HD video downlink during the nearly 22 hours of operations. An overview of the flight hardware including description of the components, diagnostics, crew procedures, flight operations, and summary of accomplishments is reported in Ref. 1. Further details of the diagnostics, tests performed, and data reduction is reported in Ref. 2. This report collects both1,2 into a single report adding methods of data digitization, reduction, and archive along with analyses and discussions of technology impacts.

microgravity↗

NASA NTRS2000

Interactive Computer Graphics

Aerospace data analysis tools that significantly reduce the time and effort needed to analyze large-scale computational fluid dynamics simulations have emerged this year. The current approach for most postprocessing and visualization work is to explore the 3D flow simulations with one of a dozen or so interactive tools. While effective for analyzing small data sets, this approach becomes extremely time consuming when working with data sets larger than one gigabyte. An active area of research this year has been the development of data mining tools that automatically search through gigabyte data sets and extract the salient features with little or no human intervention. With these so-called feature extraction tools, engineers are spared the tedious task of manually exploring huge amounts of data to find the important flow phenomena. The software tools identify features such as vortex cores, shocks, separation and attachment lines, recirculation bubbles, and boundary layers. Some of these features can be extracted in a few seconds; others take minutes to hours on extremely large data sets. The analysis can be performed off-line in a batch process, either during or following the supercomputer simulations. These computations have to be performed only once, because the feature extraction programs search the entire data set and find every occurrence of the phenomena being sought. Because the important questions about the data are being answered automatically, interactivity is less critical than it is with traditional approaches.

Kenwright, David↗

DOE OSTI2023

Experimental and Numerical Investigation of Flow Boiling in Additive Manufactured Foam Structures With Vapor Pathways

Abstract The unique properties of metal foams make them potential candidates for a range of applications, including microsystem thermal management. Using additive manufacturing to create foam-type structures can improve upon prior thermal solutions by eliminating thermal interface materials and allowing for customization/local control of parameters. In the present investigation, flow boiling in additive-manufactured metal foams is investigated both experimentally and numerically. Two test samples, one with uniform structure and the other with pathways for vapor removal, are compared both experimentally and numerically. A conjugate computational fluid dynamics and heat transfer (CFD-HT) model utilizing a three-dimensional volume of fluid (VOF) model with accompanying evaporation/condensation model provided in-depth visualization of the boiling flow phenomena. The experiments generated the thermohydraulic performance over a range of heat fluxes, demonstrating that the sample incorporating dedicated vapor pathways performed better in both pressure and heat transfer performance metrics compared to the uniform foam. Additionally, negative system-level effects (i.e., hydraulic oscillations) were shown to be abated using the vapor removal structures. The numerical model yielded further insight into the factors contributing to the improved performance. Results indicated the pathways functioned as vapor removal channels, allowing the generated vapor to vent from the foam structure into the lanes. Further computational investigations demonstrated changes in flow regimes, where the addition of vapor channels caused the flow to change from churn to annular. Bubble behavior unique to the vapor pathway structure was studied, showing stagnant regions that eject vapor into the channel.

Engineering↗

DOE OSTI2024

MOSCATO Development and Integration in Fiscal Year 2024

MOSCATO (Molten Salt Chemistry and Transport) is a multiphysics code that provides high-fidelity, coupled simulations of fluid flow, heat transfer, mass transfer, chemistry, electrochemical phenomena, and alloy evolution for molten salt equipment. In FY24, significant developments were made to the code package, enhancing its capabilities in many aspects. The improvements and advancements can be summarized as follows: 1. Implementation of tritium transport capabilities and validation with experimental data: To enable modeling of tritium and other fission gases within MSRs, we implemented gas transport within MOSCATO via inclusion of couple mass transport equations within the salt and structural alloys. Comparisons to experimental data from literature showed good agreement with respect to tritium release rates. 2. Preliminary implementation of two-phase flow models in MOSCATO: To model tritium and other gases above their solubility limits, we implemented preliminary two-phase flow models within MOSCATO to account for bubble transport. The first model adopted was the Level-Set approach, which can handle the high void fraction regime, but with a requirement for high mesh resolution thus high computational expense. In this report, we present a verification of the Level-Set method using a simple benchmark case. We also performed a demonstration of the code as applied to an experimental case involving cover gas flow through salt in an experimental vessel. The second model adopted was the Eulerian-Eulerian dispersed flow model, which is computationally cheaper but limited to low void fraction regimes, such as bubbly flow. Validation and verification have not yet been performed for the Eulerian-Eulerian approach, but a preliminary implementation was completed. 3. Validation with static corrosion experiments: Static corrosion experimental data for stainless steel coupons within molten salts was used to further validate the corrosion model in MOSCATO. To do so, we leveraged the existing models in MOSCATO and simulated the sample mass loss and mass gain phenomena. Several ion species, including Cr 2+ , Fe 2+ and H + , were simulated in salt using the PNP solver, while Cr 0 and Fe 0 were simulated with a diffusion solver in stainless steel. The mass loss of the samples was compared with experimental data, and good agreement was achieved. These combined activities served to further expand the capabilities of MOSCATO and make it more generally applicable to the full range of phenomena that can control chemistry and corrosion in molten salt reactors.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

NASA NTRS2010

A Study of Fluid Interface Configurations in Exploration Vehicle Propellant Tanks

The equilibrium shape and location of fluid interfaces in spacecraft propellant tanks while in low-gravity is of interest to system designers, but can be challenging to predict. The propellant position can affect many aspects of the spacecraft such as the spacecraft center of mass, response to thruster firing due to sloshing, liquid acquisition, propellant mass gauging, and thermal control systems. We use Surface Evolver, a fluid interface energy minimizing algorithm, to investigate theoretical equilibrium liquid-vapor interfaces for spacecraft propellant tanks similar to those that have been considered for NASA's new class of Exploration vehicles. The choice of tank design parameters we consider are derived from the NASA Exploration Systems Architecture Study report. The local acceleration vector employed in the computations is determined by estimating low-Earth orbit (LEO) atmospheric drag effects and centrifugal forces due to a fixed spacecraft orientation with respect to the Earth or Moon, and rotisserie-type spacecraft rotation. Propellant/vapor interface positions are computed for the Earth Departure Stage and Altair lunar lander descent and ascent stage tanks for propellant loads applicable to LEO and low-lunar orbit. In some of the cases investigated the vapor ullage bubble is located at the drain end of the tank, where propellant management device hardware is often located.

Zimmerli, Gregory A.↗

DOE OSTI2020

A novel, magnetically driven convergent Richtmyer–Meshkov platform

Here, we introduce a novel experimental platform for the study of the Richtmyer–Meshkov instability in a cylindrically converging geometry using a magnetically driven cylindrical piston. Magnetically driven solid liner implosions are used to launch a shock into a liquid deuterium working fluid and, ultimately, into an on-axis rod with a pre-imposed perturbation. The shock front trajectory is tracked through the working fluid and up to the point of impacting the rod through the use of on axis photonic Doppler velocimetry. This configuration allows for precise characterization of the shock state as it impacts the perturbed rod interface. Monochromatic x-ray radiography is used to measure the post-shock interface evolution and rod density profile. The ALEGRA MHD model is used to simulate the dynamics of the experiment in one dimension. We show that late in time the perturbation growth becomes non-linear as evidenced by the observation of high-order harmonics, up to n = 5. Two dimensional simulations performed using a combination of the GORGON MHD code and the xRAGE radiation hydrodynamics code suggest that the late time non-linear growth is modified by convergence effects as the bubbles and spikes experience differences in the pressure of the background flow.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

NASA NTRS1992

Lift enhancement by trapped vortex

The viewgraphs and discussion of lift enhancement by trapped vortex are provided. Efforts are continuously being made to find simple ways to convert wings of aircraft from an efficient cruise configuration to one that develops the high lift needed during landing and takeoff. The high-lift configurations studied here consist of conventional airfoils with a trapped vortex over the upper surface. The vortex is trapped by one or two vertical fences that serve as barriers to the oncoming stream and as reflection planes for the vortex and the sink that form a separation bubble on top of the airfoil. Since the full three-dimensional unsteady flow problem over the wing of an aircraft is so complicated that it is hard to get an understanding of the principles that govern the vortex trapping process, the analysis is restricted here to the flow field illustrated in the first slide. It is assumed that the flow field between the two end plates approximates a streamwise strip of the flow over a wing. The flow between the endplates and about the airfoil consists of a spanwise vortex located between the suction orifices in the endplates. The spanwise fence or spoiler located near the nose of the airfoil serves to form a separated flow region and a shear layer. The vorticity in the shear layer is concentrated into the vortex by withdrawal of fluid at the suction orifices. As the strength of the vortex increases with time, it eventually dominates the flow in the separated region so that a shear or vertical layer is no longer shed from the tip of the fence. At that point, the vortex strength is fixed and its location is such that all of the velocity contributions at its center sum to zero thereby making it an equilibrium point for the vortex. The results of a theoretical analysis of such an idealized flow field are described.

Rossow, Vernon J.↗

DOE OSTI2025

Mitigation of Boiling-Induced Thermal Degradation Using Microporous Nickel Inverse Opals Structures

Engineered microporous structures have received much attention in high-heat-flux electronics cooling due to their high thermal conductivity and permeability, and large surface area for heat transfer, but are susceptible to boiling-induced thermal degradation. Here, this study investigates the efficacy of nickel inverse opals (NiIOs) in mitigating structural degradation caused by corrosion-assisted erosion during pool boiling with water as the working fluid. First, we compared the reliability of NiIOs to copper inverse opals (CuIOs) for a 3-day pool boiling test at constant heat flux. The NiIOs demonstrated superior resistance to thermal degradation due to their inherent corrosion resistance and mechanical strength. Subsequently, we conducted a more controlled experiment to show the effect of heat flux on the degradation of the NiIOs while excluding the effect of temperature variations. Pool boiling tests of 20-μm-thickness NiIOs covering an area of ∼11 × 11 mm 2 with a 2.5 × 2.5 mm 2 heater at the center were conducted at heat flux levels of 20%, 40%, and 60% of the critical heat flux (CHF) for 3 days. The NiIOs subjected to heat flux levels of 20% and 40% CHF showed minimal degradation, while the sample subjected to 60% CHF showed erosion on the top surface due to higher bubble formation and departure rate. These results show the potential of NiIOs as a promising solution for long-term thermal management in high-power electronic devices, although design considerations for maximum allowable heat flux are necessary for reliable operation.

36 MATERIALS SCIENCE↗