Advances in structured surface fabrication strategies for enhancing boiling heat transfer : a comprehensive review

Roni, Md Rakibul Hasan (avtor), Gregorčič, Peter (avtor), Zupančič, Matevž (avtor)

Increasing global energy demand is driving the need for efficient heat dissipation techniques, especially for high heat flux applications such as electronics thermal management. Boiling heat transfer has emerged as a promising heat acquisition solution due to its ability to utilize the latent heat of vaporization during liquid-to-vapor phase transformation. However, the thermal performance of conventional plain or finned surfaces can be limited due to low nucleation site density and poor fluid wickability, which are crucial for efficient boiling heat transfer and high critical heat flux (CHF). Unlike their macroscale (> 200 µm length scales) fin counterparts, micro- and nanostructured surfaces, herein termed structured surfaces, have become a promising alternative to overcome these barriers. The selection of appropriate structured surface fabrication techniques is essential to achieve the desired surface topography, cavity size range, and enhanced boiling performance. In this review, we provide a comprehensive analysis of structured surface fabrication strategies for boiling heat transfer enhancement. We broadly classify the methods into two groups: subtractive methods such as etching and laser ablation, and additive methods such as electrochemical deposition, sintering, and coating. The effect of manufacturing process parameters on surface characteristics is discussed in detail for each fabrication technique. We present how these engineered surfaces affect boiling performance and discuss the underlying mechanisms of heat transfer coefficient (HTC) and CHF enhancement in pool and flow boiling. A comparative evaluation of the fabrication methods is provided in terms of their advantages, limitations, and effectiveness in enhancing HTC and CHF. The key challenges associated with translating lab-scale to real-life boiling applications such as scalability, long-term durability and environmental impact of the fabrication methods are critically analyzed. Finally, we propose future directions for further advancement in the field. This review aims to serve as a guideline for structured surface design for high performance and energy efficient thermal systems.

• Jezik: Angleški jezik
• Ključne besede: structured surfaces, boiling, heat transfer, laser texturing
• Vrsta gradiva: Članek v reviji
• Tipologija: 1.01 - Izvirni znanstveni članek
• Organizacija: FS - Fakulteta za strojništvo
• Status publikacije: Objavljeno
• Različica publikacije: Objavljena publikacija
• Leto izida: 2026
• Št. strani: 68 str.
• Številčenje: Vol. 273, part 2, art. 129632
• PID: 20.500.12556/RUL-189743
• UDK: 536.24
• ISSN pri članku: 1879-2189
• DOI: 10.1016/j.ijheatmasstransfer.2026.129632
• COBISS.SI-ID: 300831235
• Datum objave v RUL: 14.10.2026

Gradivo je del revije

• Naslov: International journal of heat and mass transfer
• Skrajšan naslov: Int. J. Heat Mass Transfer
• Založnik: Elsevier
• ISSN: 1879-2189
• COBISS.SI-ID: 23007493

Licence

• Licenca: CC BY-NC-ND 4.0, Creative Commons Priznanje avtorstva-Nekomercialno-Brez predelav 4.0 Mednarodna
• Povezava: http://creativecommons.org/licenses/by-nc-nd/4.0/deed.sl
• Opis: Najbolj omejujoča licenca Creative Commons. Uporabniki lahko prenesejo in delijo delo v nekomercialne namene in ga ne smejo uporabiti za nobene druge namene.

Sekundarni jezik

• Jezik: Slovenski jezik
• Ključne besede: strukturirane površine, vrenje, prenos toplote, lasersko teksturiranje

Projekti

• Financer: Drugi - Drug financer ali več financerjev
• Program financ.: Office of Naval Research
• Številka projekta: N00014–24–1–2575
• Naslov: Multidisciplinary University Research Initiative
• Akronim: MURI

• Financer: Drugi - Drug financer ali več financerjev
• Program financ.: International Institute for Carbon Neutral Energy Research
• Akronim: WPI-I2CNER