We reveal and justify, both theoretically and experimentally, the existence of a unifying criterion of the boiling crisis. This criterion emerges from an instability in the near-wall interactions of bubbles, which can be described as a percolation process driven by three fundamental boiling parameters: nucleation site density, average bubble footprint radius and product of average bubble growth time and detachment frequency. Our analysis suggests that the boiling crisis occurs on a well-defined critical surface in the multidimensional space of these parameters. Our experiments confirm the existence of this unifying criterion for a wide variety of boiling surface geometries and textures, two boiling regimes (pool and flow boiling) and two fluids (water and liquid nitrogen). This criterion constitutes a simple mechanistic rule to predict the boiling crisis, also providing a guiding principle for designing boiling surfaces that would maximize the nucleate boiling performance.

Surfaces with micrometer-scale pillars have shown great potential in delaying the boiling crisis and enhancing the critical heat flux (CHF). However, physical mechanisms enabling this enhancement remain unclear. This knowledge gap is due to a lack of diagnostics that allow elucidating how micro-pillars affect thermal transport phenomena on the engineered surface. In this study, for the first time, we are able to measure time-dependent temperature and heat flux distributions on a boiling surface with engineered micro-pillars using infrared thermometry. Using these data, we reveal the presence of an intra-pillar liquid layer, created by the nucleation of bubbles and partially refilled by capillary effects. However, contrarily to conventional wisdom, the energy removed by the evaporation of this liquid cannot explain the observed CHF enhancement. Yet, predicting its dry out is the key to delaying the boiling crisis. We achieve this goal using simple analytic models and demonstrate that this process is driven by conduction effects in the boiling substrates and, importantly, in the intra-pillar liquid layer itself. Importantly, these effects also control the wicking flow rate and its penetration length. The boiling crisis occurs when, by coalescing, the size of the intra-pillar liquid layer becomes too large for the wicking flow to reach its innermost region. Our study reveals and quantifies unidentified physical aspects, key to the performance optimization of boiling surfaces for cooling applications.

This paper presents an experimental characterization of liquid nitrogen (LN₂) flow boiling in additively manufactured minichannels. There is a pressing need of concerted efforts from the space exploration and thermal transport communities to design high-performance rocket engine cooling channels. A close observation of the literature gaps warrants a systematic cryogenic flow boiling characterization of asymmetrically heated small ( 3000 kg/m²s and pressure > 1 MPa. As such, this work presents the LN₂ flow boiling results for three asymmetrically heated additively manufactured GR-Cop42 channels of 1.8 mm, 2.3 mm, and 2.5 mm hydraulic diameters. Twenty different tests have been performed at mass flux~3805–14,295 kg/m²s, pressures~1.38 and 1.59 MPa, and subcooling~0 and 5 K. A maximum departure from nucleate boiling (DNB)-type critical heat flux (CHF) of 768 kW/m² has been achieved for the 1.8 mm channel. The experimental results show that CHF increases with increasing LN₂ flow rate (337–459 kW/m² at 25–57 cm³/s for 2.3 mm channel) and decreasing channel size (307–768 kW/m² for 2.5–1.8 mm channel). Finally, an experimental DNB correlation has been developed with 10.68% mean absolute error.

Surfaces with micrometer-scale pillars have shown great potential in delaying the boiling crisis and enhancing the critical heat flux (CHF). However, physical mechanisms enabling this enhancement remain unclear. This knowledge gap is due to a lack of diagnostics that allow elucidating how micro-pillars affect thermal transport phenomena on the engineered surface. In this study, for the first time, we are able to measure time-dependent temperature and heat flux distributions on a boiling surface with engineered micro-pillars using infrared thermometry. Using these data, we reveal the presence of an intra-pillar liquid layer, created by the nucleation of bubbles and partially refilled by capillary effects. However, contrarily to conventional wisdom, the energy removed by the evaporation of this liquid cannot explain the observed CHF enhancement. Yet, predicting its dry out is the key to delaying the boiling crisis. We achieve this goal using simple analytic models and demonstrate that this process is driven by conduction effects in the boiling substrates and, importantly, in the intra-pillar liquid layer itself. Importantly, these effects also control the wicking flow rate and its penetration length. The boiling crisis occurs when, by coalescing, the size of the intra-pillar liquid layer becomes too large for the wicking flow to reach its innermost region. Our study reveals and quantifies unidentified physical aspects, key to the performance optimization of boiling surfaces for cooling applications.