Boiling Phenomena and Heat Transfer Enhancement Effect on Micro/Nanoporous Sintered Copper Surfaces

This study experimentally investigated boiling phenomena and heat transfer enhancement on sintered Cu micro/nanoporous surfaces under saturated pool boiling conditions. To evaluate the effects of the combined micro/nanostructures, microporous Cu layers and pillar-integrated surfaces were fabricated using micro-sized (diameter <75 mm) metal powder sintering, while nanostructures were formed through thermal oxidation. Boiling experiments revealed that the boiling heat transfer coefficient (BHTC) and critical heat flux (CHF) of the microporous Cu surfaces surpassed those of the reference surface SiO2. The microporous pillar surface exhibited the best performance, demonstrating enhancements of approximately 2.7-fold and 7.3-fold in CHF and BHTC, respectively. High-speed imaging attributed this improvement to increased nucleation site density, rapid detachment and generation of small bubbles, efficient surface rewetting by capillary wicking, and liquid–vapor pathway separation enabled by the pillar geometry. Distinct transient temperature peaks and recoveries were observed on the oxidized pillar surfaces. Despite temporary overheating, strong capillary wicking from the superhydrophilic nanostructures recovered to the nucleate-boiling regime, which suppressed irreversible dryout and extended the boiling performance beyond the smooth surface CHF by 2.1 times. The results revealed that increasing the nucleation site density, enhancing the capillary-driven liquid supply, and ensuring effective separation of the vapor and liquid pathways improved the boiling heat transfer in multiscale porous structures. The sintered Cu micro/nanoporous surfaces demonstrated stable and efficient heat transfer across a wide range of heat fluxes, highlighting their potential for advanced thermal management applications and realizing optimally designed high-performance boiling surfaces.