The pool boiling experiment

The three liter boiling vessel is shown in Figure 2.9. It has sensors hanging from the top and the specimen inserted through the bottom. The top plate has a vent, cooling coil, a K-type thermocouple and an absolute pressure sensor. Temperature and pressure readings were captured by an NI 9213 module and recorded by LabVIEW. The heater and specimen are located at the bottom center of the vessel. The test specimen is levelled with the top surface of a PTFE block.

Detailed structure of heating section and the specimen is shown in Figure 2.10. The test specimen is a 2 cm × 2 cm × 9 cm aluminum block. A 2 cm × 2 cm × 0.2 cm square WatLow ULTRAMIC ceramic heater located under the aluminum blocked is used to heat the specimen. The top surface of the heater and the bottom surface of the specimen is firmly in contact with each other, secured by the force of the spring underneath the heater. A K-type thermocouple was used to measure the temperature of the heater to monitor the heating process. Another two K-type thermocouples were inserted into 0.5 × 5 mm holes in the aluminum specimen, 6.4 mm below the boiling surface, to monitor the temperature of the aluminum. DC current was supplied to the heater by a power supply (Agilent Technologies N5771A). During the boiling process, LabVIEW recorded the current and voltage of the heater, which was then used to calculated the heat flux by Equation (2.2), in which “Area”

is 2 cm × 2 cm. Also recorded were the temperature of the specimen and the boiling pool.

q UI

  Area (2.2)

w TC

Before starting the boiling deposition process, the pool is heated to degas and later sustain at near saturation temperature by a circular shape auxiliary heater located at the bottom of the vessel (Figure 2.9 (b)). When the temperature reading for the pool is near the saturation temperature and varies within the uncertainty of the thermocouple ( 0.3 K) over 10 minutes, it is considered as steady state, and the boiling deposition process can start. The DC voltage on the heater is set constant by the power supply during boiling deposition processes, so that a prescribed heat flux at the boiling surface is maintained. The pool boiling deposition process is kept at a constant heat flux for a certain length of time. The specimen temperature was utilized to calculate the boiling surface temperature by Fourier’s law of conduction, as shown in Equation (2.3), where the δ is the distance between the thermocouple hole and top specimen surface (6 mm) and k is the thermal conductivity of AA6061 (16 W/m-K).

The heat transfer driving potential ΔT is the difference between pool temperature Tpool and the specimen top surface temperature Tw (Equation (2.4)). With the above parameters calculated, heat transfer coefficient can be easily found using Equation (2.5).

Uncertainties of measurements are listed in Table 2.2. The heat loss is calculated by a model (using ANSYS) of the heating section. The modeling result is then compared to the measured temperature inside the specimen, and agreed within 0.2 K difference. This is

included in the uncertainty of the heat flux.

Near uniform heat flux was generated to the best effort. It is ensured by the following factors:

1) The heater: a special ceramic heater (ULTRAMIC) was used to heat up the specimen. According to the manufacturer (Watlow), the advanced ceramic heater construction uses aluminum nitride with a uniform grain size, and the circuit layout in the heater is optimized. Because of these, uniform temperature is achieved.

2) Flatness: Surface flatness of the heater is 0.05mm with less than 1.5 um roughness of surface finish. For the aluminum block, the top surface and bottom surface are made to be parallel under a stringent manufacturing process, carried out by the most skilled technician in the machine shop. As a result, uniformity at the heater could propagate to the top surface of the aluminum specimen.

3) Leveling: The top surface is the boiling surface, and its leveling is ensured by the sample holder and the adjustable legs of the pool, in order to ensure a horizontal surface boiling.

4) The pool: The pool is significantly larger than the specimen, and the temperature was kept at near saturation by an auxiliary heater located at the bottom of the pool.

5) The surface: Uniformity roughness and wettability of the original substrate was ensured in the preparation of the substrate, which is described in section 2.1 of the paper.

6) Insulation: The specimen was mounted in a sample holder made of PTFE by silicone. The heater was insulated inside a thick PEEK block. In addition, the whole heating section was insulated by 2in thick EPDM rubber insulation material.

In summary, uniformity was ensured from the heat source and heat conduction path to the boiling surface with minimized heat loss from the side, and the well prepared horizontal specimen surface in the controlled pool environment should lead to a near uniform boiling heat transfer coefficient. As a result, heat flux at the surface should be nearly uniform.

Experimental conditions for NBND process at various heat flux, surface roughness and nanofluid concentrations are shown in Table 2.3. After the nanofluid boiling nanoparticle deposition process, the specimen was removed carefully from the bottom of the pool, ready for wettability characterization.