Increased cooling requirements of many compact systems involving high heat fluxes demand the development of high-performance cooling techniques including immersion cooling utilizing pool boiling. This study presents the functionalization of copper surfaces to create interfaces for enhanced pool boiling heat transfer. Three types of surface structures including a crosshatch pattern, shallow channels and deep channels were developed using nanosecond laser texturing to modify the surface micro- and nanomorphology. Each type of surface structure was tested in the as-prepared superhydrophilic state and superhydrophobic state following hydrophobization, achieved through the application of a nanoscale self-assembled monolayer of a fluorinated silane. Boiling performance evaluation was conducted through three consecutive runs under saturated conditions at atmospheric pressure utilizing water as the coolant. All functionalized surfaces exhibited enhanced boiling heat transfer performance in comparison with an untreated reference. The highest critical heat flux of 1697 kW m⁻² was achieved on the hydrophobized surface with shallow channels. The highest heat transfer coefficient of 291.4 kW m⁻² K⁻¹ was recorded on the hydrophobized surface with deep channels at CHF incipience, which represents a 775% enhancement over the highest values recorded on the untreated reference. Surface microstructure was identified as the key reason for enhanced heat transfer parameters. Despite large differences in surface wettability, hydrophobized surfaces exhibited comparable (or even higher) CHF values in comparison with their hydrophilic counterparts, which are traditionally considered as more favorable for achieving high CHF values. A significant reduction in bubble departure diameter was observed on the hydrophobized surface with deep channels and is attributed to effective vapor entrapment, which is pointed out as a major contributing reason behind the observed extreme boiling heat transfer performance.

Prior studies have evidenced the potential for enhancing boiling heat transfer through modifications of surface or fluid properties. The deployment of nanofluids in pool boiling systems is challenging due to the deposition of nanoparticles on structured surfaces, which may result in performance deterioration. This study addresses the use of TiO₂–water nanofluids (mass concentrations of 0.001 wt.% and 0.1 wt.%) in pool boiling heat transfer and concurrent mitigation of nanoparticle deposition on superhydrophobic laser-textured copper surfaces. Samples, modified through nanosecond laser texturing, were subjected to boiling in an as-prepared superhydrophilic (SHPI) state and in a superhydrophobic state (SHPO) following hydrophobization with a self-assembled monolayer of fluorinated silane. The boiling performance assessment involved five consecutive boiling curve runs under saturated conditions at atmospheric pressure. Results on superhydrophilic surfaces reveal that the use of nanofluids always led to a deterioration of the heat transfer coefficient (up to 90%) compared to pure water due to high nanoparticle deposition. The latter was largely mitigated on superhydrophobic surfaces, yet their performance was still inferior to that of the same surface in water. On the other hand, CHF values of 1209 kW m⁻² and 1462 kW m⁻² were recorded at 0.1 wt.% concentration on both superhydrophobic and superhydrophilic surfaces, respectively, representing a slight enhancement of 16% and 27% compared to the results obtained on their counterparts investigated in water.

A corresponding-states correlation for predicting the critical heat flux (CHF) in pool boiling conditions is proposed, and only requires knowledge of physical property constants of the fluid at any fluid temperature: molar mass, critical temperature, critical pressure, and the Pitzer acentric factor. If a fourth corresponding equation of state (EoS) parameter is added, a more accurate CHF correlation is obtained and matches Kutateladze–Zuber prediction within ±10% in the reduced temperature range of 0.55–0.95. This way, CHF can be easily predicted for any reduced temperature within the range of correlation’s validity by only knowing basic properties of the fluid. Additionally, two corresponding-states correlations for determining the capillary length are proposed and also do not rely on any temperature- and pressure-dependent fluid properties. A simpler correlation only using the Pitzer acentric factor is shown to be imprecise, and a more complex correlation also accounting for the fourth corresponding EoS parameter is recommended. These correlations are fundamental for further developments, which would allow for accurate prediction of CHF values on functionalized surfaces through further studies on the influence of interactions of fluid properties with other parameters, such as wetting and active nucleation site density.