The present study was performed to numerically analyze the evaporation phenomena through the liquid-vapor interface and to investigate bubble dynamics and heat transfer behavior during forced convective flow boiling in a microchannel. Flow instabilities of two-phase flow boiling in a microchannel were studied as well. The main objective of this research is to investigate the fundamental mechanisms of two-phase flow boiling in a microchannel and provide predictive tools to design thermal management systems, for example, microchannel heat sinks. The numerical results obtained from this study were qualitatively and quantitatively compared with experimental results in the open literature.

Physical and mathematical models, accounting for evaporating phenomena through the liquid-vapor interface in a microchannel at constant heat flux and constant wall temperature, have been developed, respectively. The heat transfer mechanism is affected by the dominant heat conduction through the thin liquid film and vaporization at the liquid-vapor interface. The thickness of the liquid film and the pressure of the liquid and vapor phases were simultaneously solved by the governing differential equations. The developed semi-analytical evaporation model that takes into account of the interfacial phenomena and surface tension effects was used to obtain solutions numerically using the fourth-order Runge-Kutta method. The effects of heat flux 19 and wall temperature on the liquid film were evaluated. The obtained pressure drops in a microchannel were qualitatively consistent with the experimental results of Qu and Mudawar (2004).

Forced convective flow boiling in a single microchannel with different channel heights was studied through a numerical simulation to investigate bubble dynamics, flow patterns, and heat transfer. The momentum and energy equations were solved using the finite volume method while the liquid-vapor interface of a bubble is captured using the VOF (Volume of Fluid) technique. The effects of different constant heat fluxes and different channel heights on the boiling mechanisms were investigated. The effects of liquid velocity on the bubble departure diameter were analyzed. The obtained results showed that the wall superheats at the position of nucleate boiling are relatively independent of the mass flow rates at the same channel height. The obtained results, however, showed that the heat flux at the onset of nucleate boiling strongly depends on the channel height. With a decrease of the channel height and an increase of the liquid velocity at the channel inlet, the departure diameter of a bubble was smaller. The periodic flow patterns, such as the bubbly flow, elongated slug flow, and churn flow were observed in the microchannel. Flow instabilities of two-phase flow boiling in a trapezoidal microchannel using a three-dimensional model were investigated. Fluctuation behaviors of flow boiling parameters such as wall temperature and inlet pressure caused by periodic flow patterns were studied at different heat fluxes and mass fluxes. The numerical results showed large amplitude and short period oscillations for wall temperature and inlet pressure fluctuations. Stable and unstable flow boiling regime with short period oscillations were investigated. Those flow boiling regimes were not listed in stable and unstable boiling regime map proposed by Wang et al. (2007).