Thin film boiling heat transfer performance on a bionic canal system foam metal wick inspired by the Callyspongia plicifera

Thin film boiling is widely recognized as an effective strategy for thermal management of high-power density devices. In this work, a bionic canal system foam metal wick (BCFW), inspired by the canal system of Callyspongia plicifera , is presented. This aluminum based and, cost- effective porous composite structure is fabricated via a concise three- step process combining vacuum diffusion bonding, laser etching, and anodization. The BCFW enhances liquid replenishment and capillary pressure during phase-change heat transfer. Visualized thin-film boiling experiments under antigravity conditions confirm its high efficiency and reliability. A critical heat flux (CHF) as high as 331.52 W/cm² was achieved by the G0.5-W0.5 specimen, while a maximum heat transfer coefficient (HTCmax) of 113.15 kW/(m²·K) was attained by the G0.25-W0.5 specimen at a heat flux of 288.69 W/cm². Analysis of capillary transport and vapor–liquid dynamics reveals that the unique canal system structure establishes unidirectional hydrodynamic pathways, enabling the coexistence of sustained capillary liquid supply and favorable thin-film boiling. Optimal CHF arises from smaller, denser grooves (G0.5-W0.5), which provide abundant nucleation sites while preserving a continuous pore network. The highest HTCmax corresponds to a groove-to-wall width ratio of 1:2 (G0.25-W0.5), which more effectively triggers thin-film boiling. Further, this technological pathway offers an ideal core component for realizing two phase thermal management solutions that are highly efficient, reliable, cost effective, and environmentally friendly in large scale applications.