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<p>This study presents a plasma-assisted, binder-free strategy for fabricating multilayer carbon nanotube (CNT) coatings with programmable morphology for enhanced pool boiling heat transfer. A layer-by-layer electrodeposition process combined with plasma densification enables controlled architectural evolution while minimizing solvent usage and thermal budget. Three surfaces (CNT–CNT–5, CNT–CNT–10, CNT–CNT–15) were engineered to transition from dense nanoscale fibrous networks to a hierarchical micro–nanostructure. Surface characterization revealed that CNT–CNT–5/10 formed entangled nanotube mats with porosity of 53.2–65.5% and roughness <i>R</i><sub>a</sub> = 1.2–1.8&#xa0;µm, whereas CNT–CNT–15 developed embedded microcavities (mean diameter ≈3.9&#xa0;µm) within a porous CNT scaffold, achieving 89.6% porosity and <i>R</i><sub>a</sub> ≈2.5&#xa0;µm. Plasma treatment reduced the water contact angle from 78° (bare copper) to 12°, establishing a superhydrophilic regime favorable for capillary rewetting. Under saturated water pool boiling, CNT–CNT–5/10 enhanced the heat transfer coefficient (HTC) by 120–150% at moderate heat fluxes due to increased nucleation density, but exhibited limited CHF improvement. In contrast, CNT–CNT–15 simultaneously achieved 286% HTC enhancement and 88% critical heat flux (CHF) enhancement, associated with cavity-stabilized nucleation, 36% shorter bubble growth period, 2.3 times higher departure frequency, and suppressed vapor coalescence. A morphology-governed correlation integrating structural and bubble dynamics descriptors accurately captured the boiling trends. The results establish a scalable, morphology-driven framework for high-flux thermal management surface design.</p>

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Plasma-densified CNT hierarchical coating surfaces for enhanced pool boiling: morphology–bubble dynamics coupling and performance correlation

  • 期刊论文

  • 发表日期：

    2026年4月25日

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  • M. Selvamuthukumar,
  • Sanjay Kumar Gupta

摘要

This study presents a plasma-assisted, binder-free strategy for fabricating multilayer carbon nanotube (CNT) coatings with programmable morphology for enhanced pool boiling heat transfer. A layer-by-layer electrodeposition process combined with plasma densification enables controlled architectural evolution while minimizing solvent usage and thermal budget. Three surfaces (CNT–CNT–5, CNT–CNT–10, CNT–CNT–15) were engineered to transition from dense nanoscale fibrous networks to a hierarchical micro–nanostructure. Surface characterization revealed that CNT–CNT–5/10 formed entangled nanotube mats with porosity of 53.2–65.5% and roughness Ra = 1.2–1.8 µm, whereas CNT–CNT–15 developed embedded microcavities (mean diameter ≈3.9 µm) within a porous CNT scaffold, achieving 89.6% porosity and Ra ≈2.5 µm. Plasma treatment reduced the water contact angle from 78° (bare copper) to 12°, establishing a superhydrophilic regime favorable for capillary rewetting. Under saturated water pool boiling, CNT–CNT–5/10 enhanced the heat transfer coefficient (HTC) by 120–150% at moderate heat fluxes due to increased nucleation density, but exhibited limited CHF improvement. In contrast, CNT–CNT–15 simultaneously achieved 286% HTC enhancement and 88% critical heat flux (CHF) enhancement, associated with cavity-stabilized nucleation, 36% shorter bubble growth period, 2.3 times higher departure frequency, and suppressed vapor coalescence. A morphology-governed correlation integrating structural and bubble dynamics descriptors accurately captured the boiling trends. The results establish a scalable, morphology-driven framework for high-flux thermal management surface design.