Surface wettability is known to have a major influence on the ebullition characteristics of a bubble growing from a solid surface. Yet, simplistic static characterization of the wetting behavior is still relied upon to indicate performance characteristics during boiling. In this study, a theoretical framework is developed for the wetting and dewetting processes occurring during bubble growth based upon the dynamic contact angles. This framework is incorporated into adiabatic volume-of-fluid simulations to capture the influence of the surface wettability on contact line and contact angle dynamics during bubble growth and departure. The simulations span a large range of dynamic wetting behaviors and fluid properties. The receding contact angle is shown to govern the early stages of bubble growth as the contact line recedes outward from the bubble center and is the dominant wetting characteristic that determines the maximum contact diameter and departure size. The advancing contact angle dictates the departure morphology as the contact line retracts inward and has a secondary role in determining the departure size. Following, improved reduced-order models are developed that establish fluid-property-independent correlations for the maximum contact diameter and departure diameter as a function of the dynamic contact angles. The results call for the need to redefine wettability classifications based on dynamic contact angles rather than static contact angle in the context of boiling. Hygrophilicity and hygrophobicity are redefined in this context, and an additional classification, ambiphilicity, is introduced for boiling surfaces exhibiting low receding contact angles and high advancing contact angles. (C) 2021 Elsevier Ltd. All rights reserved.

Decades of prior study has yet to fully disentangle the complex transport mechanisms that are attributed to highly effective heat transfer during boiling. Rational design of enhanced surfaces to maintain lower surface temperatures during boiling requires improved insight into the individual heat transfer processes and their dependence on surface characteristics. This study seeks to advance the understanding of the fundamental role that surface wettability plays in determining the relative contributions of different heat transfer mechanisms and on the overall heat transfer efficacy during bubble growth. Two-phase, diabatic simulations of single bubble growth considering interfacial phase change and a custom dynamic contact angle framework are employed to investigate how the distinct contact-line and bubble dynamics that are experienced on hygrophilic, hygrophobic, and ambiphilic surfaces impact heat transfer. The local surface temperature and heat flux profiles underneath the bubble are examined during the receding, pinning, and advancing stages of bubble growth to explore the dominant heat transfer modes at each stage. The results indicate that both hygrophilic and ambiphilic surfaces are promising candidates for the development of enhanced surfaces, but for different reasons related to microlayer heat transfer versus nucleation characteristics, respectively. Target ranges for the dynamic receding and advancing contact angles within each wettability regime are suggested to inform design of surfaces with tailored wettability that maximize performance. These findings indicate that the contact line dynamics play an important role in determining the heat transfer efficacy of a surface and provide a framework for the development of enhanced boiling surfaces. (c) 2021 Elsevier Ltd. All rights reserved.

Using additive manufacturing techniques, a ceramic heat exchanger was optimized for a concentrating solar power (CSP) electric power plant with a corrosive molten salt at atmospheric pressure as the solar field heat transfer fluid and supercritical carbon dioxide at 200 bar as the power block fluid. Temperatures ranged from 750 degrees C to 540 degrees C. The plant heat exchanger was optimized for heat transfer and stress using 1 m(3) modules arranged in parallel. Heat transfer was optimized using COMSOL Multiphysics software resulting in a unique semi-elliptical cross section for the fluid flow channels in a counter-flow configuration. Counter-flow was made possible through additive manufacturing of the fluid headers as part of each modular heat exchanger thus producing the entire module as a single piece and minimizing cost. Using reasonable parametric values, a heat exchanger module was optimized to 0.5 MW/m(3), and a section of it was manufactured including the fluid headers. Parametric studies showed the potential for a module to reach 3.5 MW/m(3). (C) 2020 Elsevier Ltd. All rights reserved.

Despite extensive study of boiling processes and their widespread use in industry, critical interactions between the fluid and surface during boiling remain poorly understood. Simplistic, static descriptions of the contact angle are still relied upon to describe the effects of surface wettability on dynamic interfacial processes that govern boiling. This work demonstrates the critical role of the dynamic wettability characteristics of a surface on bubble growth dynamics and boiling performance. In spite of their superior nucleation behavior, hydrophobic surfaces have received little attention for boiling applications due to their typically premature transition from efficient nucleate boiling to inefficient film boiling. Evaluation of hydrophobic surfaces with high contact angle hysteresis reveals that the heat transfer efficacy of these surfaces can be exploited in boiling, so long as the receding contact angle of the surface is sufficiently small to mitigate vapor spreading and thereby extend the nucleate boiling regime. A new paradigm of textured boiling surfaces - parahydrophobic surfaces that exhibit the "petal effect" and mimic the wetting behavior of a rose petal - are shown to have untapped potential in boiling applications resulting from highly hydrophobic behavior coupled with low receding contact angles. (C) 2019 Elsevier Ltd. All rights reserved.

A variety of industrial applications such as power generation, water distillation, and high-density cooling rely on heat transfer processes involving boiling. Enhancements to the boiling process can improve the energy efficiency and performance across multiple industries. Highly wetting textured surfaces have shown promise in boiling applications since capillary wicking increases the maximum heat flux that can be dissipated. Conversely, highly nonwetting textured (superhydrophobic) surfaces have been largely dismissed for these applications as they have been shown to promote formation of an insulating vapor film that greatly diminishes heat transfer efficiency. The current Letter shows that boiling from a superhydrophobic surface in an initial Wenzel state, in which the surface texture is infiltrated with liquid, results in remarkably low surface superheat with nucleate boiling sustained up to a critical heat flux typical of hydrophilic wetting surfaces, and thus upends this conventional wisdom. Two distinct boiling behaviors are demonstrated on both micro- and nanostructured superhydrophobic surfaces based on the initial wetting state. For an initial surface condition in which vapor occupies the interstices of the surface texture (Cassie-Baxter state), premature film boiling occurs, as has been commonly observed in the literature. However, if the surface texture is infiltrated with liquid (Wenzel state) prior to boiling, drastically improved thermal performance is observed; in this wetting state, the three-phase contact line is pinned during vapor bubble growth, which prevents the development of a vapor film over the surface and maintains efficient nucleate boiling behavior.

Surface wettability is typically characterized by measuring the static contact angle of a sessile droplet placed on the surface. For extremely wetting surfaces on which liquid spontaneously spreads into a thin liquid film, the near-zero static contact angle is not amenable to measurement and does not fully describe the wetting behavior. There are unmet needs in microfluidics, boiling heat transfer enhancement, and antifog-ging applications for a metric to characterize highly wetting (i.e., superhydrophilic) textured surfaces based on their capillary driven liquid pumping performance, as a supplement to the contact angle for this highly wetting regime. To describe the wetting behavior, the textured surface can be approximated as a thin porous layer through which the liquid spreads. An analytical model is developed for the volumetric flow in this layer, which reveals, a Single superhydrophilicity metric that captures the wetting behavior for a given liquid. A simple experimental approach is proposed to characterize this metric by measuring the volumetric liquid intake into the surface from a filled capillary tube. This approach is validated by characterizing micropillared superhydrophilic surfaces of known geometry; the predicted and measured wetting behaviors show good agreement. The metric proposed in this study offers a simple approach for accurately characterizing and differentiating highly wetting surfaces based on their liquid pumping ability.

The design of structured surfaces for increasing the heat flux dissipated during boiling and evaporation processes via enhanced liquid rewetting requires prediction of the liquid meniscus shape on these surfaces. In this study, a general continuum model is developed to predict the three-dimensional meniscus shape of liquid films on micro/nanostructured surfaces based on a minimization of the system free energy that includes solid-liquid van der Waals interaction energy, surface energy, and gravitational potential. The continuum model is validated at the nanoscale against molecular dynamics simulations of water films on gold surfaces with pyramidal indentations, and against experimental measurements of water films on silicon V-groove channels at the microscale. The validated model is used to investigate the effect of film thickness and surface structure depth on the meniscus shape. The meniscus is shown to become more conformal with the surface structure as the film thickness decreases and the structure depth increases. Assuming small interface slope and small variation in film thickness, the continuum model can be linearized to obtain an explicit expression for the meniscus shape. The error of this linearized model is quantitatively assessed and shown to increase with increasing structure depth and decreasing structure pitch. The model developed can be used for accurate prediction of three-dimensional meniscus shape on structured surfaces with micro/nano-scale features, which is necessary for determining the liquid delivery rate and heat flux dissipated during thin-film evaporation. The linearized model is useful for rapid prediction of meniscus shape when the structure depth is smaller than or comparable to the liquid film thickness.