An advanced superwicking aluminum material based on a microgroove surface structure textured with both laser-induced periodic surface structures and fine microholes was produced by direct femtosecond laser nano/microstructuring technology. The created material demonstrates excellent wicking performance in a temperature range of 23 to 120 °C. The experiments on wicking dynamics show a record-high velocity of water spreading that achieves about 450 mm/s at 23 °C and 320 mm/s at 120 °C when the spreading water undergoes intensive boiling. The lifetime of classic Washburn capillary flow dynamics shortens as the temperature increases up to 80 °C. The effects of evaporation and boiling on water spreading become significant above 80 °C, resulting in vanishing of Washburn’s dynamics. Both the inertial and visco-inertial flow regimes are insignificantly affected by evaporation at temperatures below the boiling point of water. The boiling effect on the inertial regime is small at 120 °C; however, its effect on the visco-inertial regime is essential. The created material with effective wicking performance under water boiling conditions can find applications in Maisotsenko cycle (M-cycle) high-temperature heat/mass exchangers for enhancing power generation efficiency that is an important factor in reducing CO₂ emissions and mitigation of the global climate change.

A novel multifunctional material with efficient wicking and evaporative functionalities was fabricated using hierarchical surface nano-/microstructuring by femtosecond laser micromachining. The created material exhibits excellent multifunctional performance. Our experiments in a wind tunnel demonstrate its good wicking and evaporative functionalities under the conditions of high-temperature airflows. An important finding of this work is the significantly enhanced evaporation rate of the created material compared with the free water surface. The obtained results provide a platform for the practical implementation of Maisotsenko-cycle cooling technologies for substantially increasing efficiency in power generation, thermal management, and other evaporation-based technologies. The developed multifunctional material demonstrates long-lasting wicking and evaporative functionalities that are resistant to degradation under high-temperature airflows, indicating its suitability for practical applications.

We experimentally demonstrate boiling suppression in a water film confined within superhydrophilic hierarchical nano/microstructured surfaces, enabling intense interfacial steam generation without bubble formation at the boiling point. Leveraging this phenomenon, we develop a high-temperature dew point evaporative cooler capable of reducing hot airflow from 437 °C to below ambient temperature. The cooler also performs effectively below the boiling point, lowering inlet air from 43 °C to 16.7 °C. These findings open pathways for potential practical applications of dew point evaporative cooling in power generation, internal combustion engines, and generative AI systems.