It is widely established that flow boiling, being a direct cooling technique also employing the latent heat of the fluid, has the potential to be more efficient than being useful in single-phase conventional cooling methods. This results in considerable potential for thermal management in many fields like microelectronics, space technology, thermal power plants, etc. The increasing demand for heat dissipation, consequent to component miniaturization, has pushed the development of new strategies for enhancing heat transfer efficiency, such as employment of functionalized surfaces. This review aims to describe in detail the current status of technology related to flow boiling heat transfer enhancement via micro/nanoscale surface functionalization. Key objectives are an increased nucleation site density and enhanced bubble dynamics. The vast majority of findings show favorable heat transfer performance, evidenced by an earlier onset of boiling (ONB), an improved flow boiling heat transfer coefficient (HTC), and an ameliorated critical heat flux (CHF). Increased pressure drop is a serious concern in certain application cases. Nanoscale textures mainly enhance capillary wicking to nucleation sites, thus being more effective in combination with microscale textures that define fixed nucleation sites. Degradation effects need to be more thoroughly and systematically characterized for application cases. Extra effects related to the manufacturing process can be easily overlooked, but one should be aware of their possible existence when drawing conclusions. Finally, the implementation of enhanced surfaces in mainstream applications is hindered by the absence of general predictive design tools for different channel configurations/materials, fluids, and operating conditions. A more universal understanding of the basic mechanisms involving texture geometry is needed in this aspect.

This work addresses enhancing flow boiling heat transfer via the use of engineered surfaces possessing specific novel geometries created via femtosecond laser texturing. Surface functionalization can result in improved, more controlled, and denser nucleation as well as controlled surface rewetting, leading to reduced incipient superheats, higher heat transfer coefficients, reduced flow instabilities, and increased critical heat fluxes with respect to a non-modified reference surface. Specifically, this study investigates how bubble dynamics and heat transfer performance are affected by three different surface textures fabricated on 200 µm thick 316L stainless steel foils using a femtosecond (fs) laser. The examined textures consist of inclined (=45°) microgrooves, inclined (=45°) conical microholes, and laser-induced periodic surface structures (LIPSSs). Each textured surface’s degree of heat transfer enhancement is assessed with respect to a plain reference surface in identical operating conditions. The working fluid is PP1, a replacement of 3M™ FC-72 in heat transfer applications. Among the tested surfaces, submicron-scale LIPSSs contribute to the rewetting of the surface but only show a slight improvement when not combined with bigger microscale structures. The inclined grooves result in the most gradual onset, showing almost no incipient overshoot. The inclined conical microholes achieve superior results, improving heat transfer coefficients up to 70% and reducing the incipient temperature up to 13.5 °C over a plain reference surface.