Design, synthesis, and characterization of hybrid micro-nano surface coatings for enhanced heat transfer applications

Metal particles coating is extensively used for surface coating a wide range of application including thermal management of electronics, concentrating photovoltaics, sensors and nuclear power plants. Both micro and nano-scale surfaces have been proven to show an enhanced two-phase heat transfer performance by varying surface properties like area, wettability, and roughness. To combine the unique features of both micro and nano-scale surface coatings, this study presents the design, synthesis, and characterization of new hybrid micro-nano scale surface coating by a new two steps approach. Five different types of surfaces; namely, plain nanocoated (PNC), uniform micro-porous (UMP), uniform hybrid micro-nano porous (UHMNP), 2-D modulated microporous (MMP) and modulated hybrid micro-nano (MHMNP) surfaces were fabricated. A new two steps approach of hot-pressing followed by nucleate boiling is used for the fabrication of these surfaces. Successful coating of hybrid micro-nano scale coating was achieved. Considering the critical surface properties of micro and nanoscale coatings, new hybrid micro-nano surfaces have been characterized for SEM, wettability, roughness test. The comparative analysis of these new hybrid coating is also performed with micro coated and uncoated surfaces. With the coating of nanoparticles, the average roughness of PNC surface increased by 4.67 times and that of hybrid micro-nano particle surface by 2.3 times. The deposition of nanoparticles resulted in an increase in contact angle for PNC surface, while the contact angle of hybrid micro-nano surfaces decreases from 126.4° to 82.1°.