Surface modification techniques for cooling by impinging jets-a review

Abstract

Keywords: Heat Transfer Enhancement; Jet Impingement; Heat Transfer Coefficient; Surface Modification; Roughness; Surface Coating

Introduction

With rapid advancements and miniaturizing, the need for faster heat removal rates is becoming a necessity nowadays. Heat transfer enhancement, though can be achieved by many mechanisms but various techniques such as use of fins, increasing the surface roughness or employment

of various types of surface coating are used primarily to increase the convective heat transfer. Use of extended surfaces such as pin fins, plate fins, vortex promoters are intended to cause enhanced mixing of the fluid by providing turbulence to the flow. This is turn increases the secondary flows and more vortex regions are generated. These vortex regions and secondary flows result in increased secondary

*Corresponding author. *E-mail address: ajoy@debbarma.me This paper was recommended for publication in revised form by Editor Mustafa Kılıç Published by Yıldız Technical University Press, İstanbul, Turkey Copyright 2021, Yıldız Technical University. This is an open access article under the CC BY-NC license (http://creativecommons.org/licenses/by-nc/4.0/).

advection of the heat from the surface. Moreover, higher turbulence levels cause increased shear and create velocity gradients for notable flow volumes. This further causes an increase in the turbulence production which then causes higher heat removal rates. Also, the added increase in the convective surface area results in heat transfer enhancement to some extent. Heat transfer enhancement by roughness elements can be understood by visualizing the flow patterns and turbulence intensity. Roughening up the surface includes employing dimples, protrusions, ribs of various shapes and sizes, use of pedestals etc. For low values of Reynolds number, roughness elements have a little effect on the Reynolds number. The flow is then considered aerodynamically smooth. But, for higher Reynolds numbers, the roughness elements dominate the momentum transport so much so, that the viscous effects are eventually nullified. Roughening increases, the swirl which in turn, affects the turbulence characteristics of the flow. With increase in the degree of the swirl, the rate of entrainment of surrounding fluid and the rate of jet velocity decay are all increased, resulting in higher heat transfer. But, as much as the roughening of the surface increases the heat transfer rate, the associated friction factor also increases. Thus, the higher heat transfer rates should also justify the added pumping power requirement. Additionally, the increased convective surface area provided increased number of nucleation sites which in turn also plays a role in the higher heat removal rates. Enhancement by applying the surface coating occurs by establishing finer and finer control over porosity and surface roughness. Thinner coating layers over the surface reduce thermal resistance and thermal stresses. This in turn has been proven to enhance Critical Heat Flux. Coating materials including nanoparticles have higher thermal conductivity due to the presence of suspended solid particles. They have displayed that the liquid surface temperature gets reduced near the non-wetting region, resulting in the formation of a surface temperature gradient, thus leading to a secondary flow. These secondary flows are responsible for additional turbulence, enhancing the rate of heat dissipation. Fabis et al. [1] in their study confirmed that nearly 60% of failures of electronic components are caused due to thermal stresses. Management of thermal stresses is of prime importance, especially at elevated rates of the order of 1MW/m2. Lee et al. [2] stated that for every 10 degrees rise in the junction temperature, the failure rate of the component nearly doubles. Jet impingement heat transfer poses a good solution to the problem at hand. Impinging jets are used in numerous applications ranging from cooling of electronic equipment [3], cooling involved in glass manufacturing [4], food processing [5], Nuclear Power plants in case of Loss of Cooling Agent (LOCA) [6], Steel industries during strip rolling [7], manufacturing of optical fiber [8], Fire Suppression mechanism [9], Cooling of Turbine blades [10] and plenty more. For systems that use nucleate boiling as extensive heat transfer mode such as Pressurized Water

Reactor (PWRs) or cooling as an Emergency Core Cooling System (ECCS), the critical heat flux provides an upper restriction to the Nucleate boiling. It has been stated that a 32% increase in the Critical Heat Flux would result in a 20% power density uprate in current plants [11]. A lot of reviews have been presented in this context, but application-based techniques still have a limited number of comprehensive and detailed literature published on them. The following paper thus presents a review on the three types of surface modification techniques for impinging jets, possible applications, and future scope of the techniques. USE OF EXTENDED SURFACES (FINS) Heat sinks being one of the most important parts of the structure of a microchannel has seen various developments over the years. These incudes use of pin fins [12–17], use of plate fins [18–20] and various other types of extended surfaces[21–23]. Increasing the surface area leads to increase in number of nucleation sites which consequently results in increase in the rate of heat transfer. Using R134a as a coolant, Ndao et al. [12] conducted experiment to study the effect on flow boiling when micro pin fins of various shapes are attached to the surface (See Figure 1). Heat transfer at elevated rates was observed. The effect was even more pronounced for high velocity coolant impingement. In fact, increase in the diameter of the pin fins led to faster heat transfer rates. This happened due the smaller flow area and consequent higher velocity. But smaller flow areas result in pressure drop. Thus, for the constant pressure drop, the pin fin with larger flow area will perform better. Circular and square micro pin fins resulted in better thermal behavior than the hydrofoil micro pin fin. Ndao et al. [13] later in their study conducted a study for cross flow using circular, square, hydrofoil and elliptical (See Figure 2) pin fin arrangements (See Figure 3). The comparative results were plotted (See Figure 4). The circular followed by the square pin fins presented the highest heat transfer coefficients at given Reynolds number. Lack of significant secondary flows were coined as a possible cause for low heat transfer coefficient observed in elliptical and hydrofoil pin fins, but presence of pin fins of any shape resulted in enhancement of heat transfer coefficient. For extended surfaces, the enhanced cooling is mostly achieved by geometric modifications. Kim et al. [20] optimized the plate fin height and which resulted in a 50% increment for the fin heat sink performance than the conventional heat sink (See Figure 5). Wong and Indran [18] analysed the effect of fillet profiles on heat transfer for a plate fin heat sink. Mesalhy and Sayed [19] in their study using an entropy generation minimization technique reported that using the narrow jets are better for short fins with lower fin number. The studies concerning pin fin and plate fin do however pose one question, which one has the better thermal performance? Few studies in the past have tried to shed some light on this area with respect to

Figure 1. (a) Micro device(b) Micro pin fin geometries-circular, square, hydrofoil [12]

Figure 3. 3-D view of pin fins A) Circular B) Elliptical, C) Hydrofoil D) Square [13].

Figure 4. Effect of pin fins on heat transfer coefficients [13].

jet impingement [24–26]. Kondo et al.[24] in his analysis stated that the optimized pin fin heat sinks have 40% more thermal resistance than the optimized plate fin heat sinks. Li et al. [25] stated that pin fins are superior to plate fins. However, these conflicting conclusions were later answered later by Kim et al. [26] when they compared the thermal resistance. It was concluded that pin fin heat sinks are better for smaller dimensionless pumping power and larger dimensionless length of heat sink and vice- versa. Pin fin porosity gives an advantage of favorable flow condition and less pressure drop. Thus, it plays an important role in heat augmentation studies. Increase in the porosity leads to increase in the surface area which consequently leads to better heat transfer performance. Zhao et al. [14] in their numerical study stated that the pin fin porosity value of 0.75 and the pin fin location angle of 30 degrees for a micro square pin fin for cooling are the optimum values. Chiu et al. [15] studied pin fin arrangement and concluded that the arrays of smaller pin diameter offer better heat transfer with lower thermal resistance and hence are suitable for thinly dispersed devices. Consequently, arrays of large pin diameters were advantageous for denser devices. They also concluded that the porosity above 0.7 had an impact on the thermal resistance. Prajapati [16] conducted a parametric study to optimize the pin fin height in a rectangular parallel microchannel numerically. For heat flux varied between 100 to 500 kW/m2, Reynolds number from 100 to 400 and fin height ranging from 0.4 to 10mm, he concluded that increasing fin height up to 0.8mm displayed heat transfer enhancement and the best possible results were obtained at this value (See Figure 6) and further increase in fin height resulted in decrement of heat transfer. The fin height of

Use Of Roughness Elements

Augmentation in heat transfer through use of extended surfaces happen due to increase in convective surface area and increased flow turbulations. Another way of enhancement in heat transfer is by increasing the wetted are This can be achieved by roughening up the surface. By doing that, viscous sublayer gets disturbed and transition to turbulence happens faster thus leading to higher values of heat transfer coefficients. Celik [40] in his experimental study analysed the effect of roughening up the surface for the circular and co-axial impinging jets. The roughness elements used were 20 dimples of 0.5 mm base, 0.5 mm height and

Surface Coating

Various methods of surface coating have been studied for the heat transfer phenomenon over the years, but lack of comprehensive and detailed studies was found concerned with the use of jet impingement. Surface properties like wettability, porosity and coating thickness can be easily controlled by this technique and significant enhancement in the heat transfer is achievable owing to these parameters. Nazari and Saedodin [58] used the electrochemical coating- anodizing process to coat a metallic layer of aluminum oxide on an aluminum surface. Gupta and Misra [59] used Copper-Aluminum oxide nanocomposite coatings. An increase in the Critical Heat Flux was reported by both studies. In a follow up study by Gupta and Misra [60], effects of two- step electrodeposition technique was studied. An enhancement of 86% with respect to bare copper surface was reported when Copper- Titanium dioxide was developed on a copper surface. Owing to enhanced wettability, similar observations were made when the coating was done by Physical Vapor Deposition (PVD) process. Das et al. [61] found an enhancement of 58% in heat transfer coefficient for the coating of silicon oxide layer. Owing to increase in surface to volume ratio, 80% enhancement in the heat transfer coefficient was obtained with Silicon dioxide coating in another study by Das et al. [62]. The Atomic Vapor deposition process for heat transfer enhancement is also employed by a few researchers. Feng et al. [63] reported a two-fold enhancement on a Platinum wire in de- ionized water when coated with Alumina. Similar observations

Figure 17. Atomic Force Microscopic image of TiO2 surface [65].

were also made for surface modifications during a study of pool boiling by Ha and Graham [64]. Dip coating methods are also prevalent for heat transfer enhancement because they provide a greater number of nucleation sites. Ray et al. [65] explored the Titanium dioxide thin film coating (100nm and 200nm) on a copper surface experimentally (See Figure 17). Plane and film thickness Nano coated type of copper heating surfaces of diameter 9mm were prepared. A maximum of 36.91% and 44.93% enhancement in heat transfer coefficients was reported on 100nm and 200nm Titanium dioxide coated surface. Hendricks et al. [66] in their experiment used Zinc oxide nanostructures deposition on Aluminum and Copper substrate. Superior heat transfer characteristics were observed in both the samples for nanostructured surfaces. A 10x times enhancement in heat transfer and 4x times improvement in critical heat flux was reported for nanostructured surfaces over the bare Aluminum substrate. Wang et al. [67] reported an increase in the Critical Heat Flux through controlling the surface chemical properties. Hu et al. [68] reported an increment of 160% in the Critical Heat Flux due to the presence of the Nano porous surface coatings. Liu and Wang [69] reported heat transfer enhancement and avoided fouling by studying the effects of coating a Titanium dioxide layer. Joseph et al. [70] used Nano Copper (II) oxide coating on Stainless Steel 316 and reported a maximum of 30% increment in the boiling heat transfer coefficient on the coated surface as compared to its uncoated counterpart. Increase in the number of nucleation sites (Figure 18 clearly shows more nucleation sites in (a) as compared to its counterpart in (b) and (c)) since it was rougher and had more Nano sized coating. This led to the enhancement in the heat transfer. Compared to the uncoated surface, a 30% heat transfer enhancement was reported. Zhao et al. [71] prepared a porous surface by diffusion bonding on a copper mesh surface. The rest of the surface was then heated and subjected to jet impingement cooling. The results displayed an enhancement in the heat transfer over the standard untreated copper mesh. Joshi and Dede [72] investigated effect of multi-scale porous surfaces. The heat transfer coefficient and pressure drop parameters were reported. Results were reported for Porous coated flat; pin-fin, open tunnel, and closed tunnel structures and the porous coated pin fin surfaces displayed the highest heat transfer enhancement. Negeed et al. [73] studied the impact of a small droplet and its behavior on a heated hydrophilic surface. Empirical relations for the effect of surface wettability, contact angle, droplet velocity and droplet size are presented in their study. Forrest et al. [74] studied nanoparticle thin film coating effects when applied layer by layer to a nickel wire. The surfaces showed hydrophobic and hydrophilic properties depending on their final treatment. A 100% enhancement in Critical Heat Flux was found when the wire was treated with fluorosilane. This effect is visible in Figure 19 where (a) is the bare nickel wire and (b) is a coated nickel wire. The boiling heat transfer was found to be increasing with

Figure 18. Smaller grain size leading to a greater number of nucleation sites [70]. decrease in surface wettability. Change in wettability or induction of roughness are the two effects which are studied the most when surface coatings are applied. Mohammadi et al. [75] studied effect of wettability on a silicon block. Significant changes in the critical heat flux were reported. Maynes et al. [76] brought forward the comparative study on hydraulic jump for hydrophobic, hydrophilic, and Super hydrophobic surfaces with ribs and cavities pattern on them and presented a local film thickness model to describe his results. Akdag et al. [77] reported the effect of the synthetic jet on the heat transfer for a flow over the flat plate. The smoke wire method was used for flow visualization of the

heat transfer mechanism. The disruptive behavior of the hydrodynamic boundary layer on the heat transfer actuator was revealed in the experiment.

Concluding Remarks

A review on heat transfer by impinging jets has been presented in this paper. This review includes various surface modifications for impinging jets. Three modifications are presented in this paper. On a broader look, all three modifications stated above had displayed higher degree of enhancements. Now, the question here lies that which modification is best suited for which type of application. Extended surfaces

Figure 19. Nickel wire- (a) bare and (b) hydrophobic at same heat flux [74].

like pin fins, plate fins, pedestals result in secondary flows and an increment in the convective heat transfer area. The research work is motivated for the areas such as microelectronics fabrications like transistor chips, small heat sources like thermoelectric generators, or use in the Integrated circuits by passive methods. Though not possible everywhere due to space constraints, other techniques have to be looked upon. Induction of the roughness elements on to the targeted surface area to disturb the flow cause early turbulence which in return leads to faster cooling rates. Roughness induction techniques are used primarily in the duct of solar air heater, solar dryer, gas turbine airfoils and blades etc. Use of surface coatings provides versatility in its use. Application areas stated for the above two methods, heat exchangers etc. see use of coatings to achieve higher heat transfer rates. One of the most recent innovations i.e., Use of special surface coatings by methods like nanoparticle coatings, Physical Vapour Deposition (PVD), Atomic Layer Deposition Method, Vacuum Glancing method, applying coating coatings to make the surface hydrophobic, hydrophilic leads to higher heat transfer rates and is being used more and more due to simplicity associated with its use.

Conclusion

The advantages that the modifications during the nanoparticle coating presents are huge, but details regarding the nanoparticle-surface adsorption phenomenon still needs to be understood. Porous coatings such as by film condensation have provided good temperature drops and are an interesting field for possible future, but micromanaging the parameters like thickness, which influences heat transfer rate directly still provides new difficulties. Integration of two or more techniques such as nanoparticle coatings over a dimpled surface, a dimple-protrusion array, vortex turbulators and surface coatings presents an interesting area of research and numerous possibilities. Primarily, the use of such hybrid techniques can in turn, give us better results. Use of dimples and protrusions to induce the roughness has displayed good results but further details like optimum depth, shape, angles etc. still need some work to be reported on them. Use of other techniques like nanoparticles in the coolant fluid is also a field of interest for the researchers nowadays. Various techniques like encapsulation of the nanoparticles are being studied and reviewed. Various Phase Change Materials (PCMs) can be used as a heat storage medium for the targeted surface thus reducing the frequency of the jet. Use of PCM’s in conjunction with the impinging jets to effectively bring down the economics of the cooling mechanism. Thus, making it a more viable solution to address heat removal problems. The use of dimples and protrusions to induce the roughness has displayed good results but further details like optimum geometric parameters and application-specific roughness elements still need some work to be conducted on them. The use of other techniques like nanoparticles in the coolant fluid is

also a field of interest for researchers nowadays. Various techniques like an encapsulation of the nanoparticles are being studied and reviewed. Various Phase Change Materials (PCMs) can be used as a heat storage medium for the targeted surface thus reducing the frequency of the jet. Use of PCM’s in conjunction with the impinging jets to effectively bring down the economics of the cooling mechanism. Thus, making it a more viable solution to address heat removal problems.

Data Availability Statement

The authors confirm that the data that supports the findings of this study are available within the article. Raw data that support the finding of this study are available from the corresponding author, upon reasonable request.

Conflict Of Interest

The author declared no potential conflicts of interest with respect to the research, authorship, and/or publication of this article.

Ethics

There are no ethical issues with the publication of this manuscript.

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