Experimental Investigation and Predictive Modeling of Two-Phase Flow Resistance in Superhydrophilic Bi-Porous Microstructures

Superhydrophilic micro/nano-porous media have extensive applications in electronic thermal management and energy storage systems. Predicting two-phase pressure drop in complex porous structures is of great importance for system design and optimization while remaining highly challenging. This study systematically investigates the two-phase flow resistance characteristics of bi-porous microstructures with multiple particle sizes and porosities under varying boiling regimes. Experimentally, porous samples were fabricated via vacuum sintering using nickel powders and pore-forming agents (CaCl2), which exhibit superhydrophilicity and enhanced wicking characteristics. A visualized experimental platform was constructed to investigate the impact of pore size combinations, flow velocities, and boiling states on pressure drop. The dataset obtained through multi-factor saturated boiling experiments was further used to derive a semi-empirical model for the two-phase flow pressure drop based on the classic Kozeny-Carman (K-C) and Akagi-Chisholm (A-C) correlations. Results show that the pore size combinations and boiling states have a significant impact on the resistance performance. The proposed model achieves an average prediction deviation below 15.7%, confirming its reliability and its effectiveness as a design framework for optimizing high-capillary-force porous wicks in advanced thermal management systems.