Experimental and Visualization Study of Flow Boiling in Open Rectangular Microchannel with Large Aspect Ratio

This experimental study comparatively investigates flow boiling performance and mechanisms in open and closed rectangular microchannels (ORMs/CRMs) with a high aspect ratio of 4. Fabricated on a copper substrate and sealed with a transparent window for visualization, the systems were tested using refrigerant R245fa. Experiments spanned mass fluxes from 89 to 545 kg/m2·s and heat fluxes from 6.3 to 218.5 W/cm2 at an inlet temperature of 14 °C. Flow visualization reveals that the ORM configuration accelerates the transition from bubbly to slug and churn flow regimes and facilitates a unique stratified flow pattern absent in the CRM. Quantitatively, the ORM enhances the heat transfer coefficient by 4.2–14.1% while reducing the system pressure drop by 11.5–58.6% within the low mass flux range (89–269 kg/m2·s). Conversely, at a high mass flux of 545 kg/m2·s, the ORM’s pressure drop increases substantially by 29.9–246.8%, attributed to significant two-phase losses in the top-gap region. As heat flux increases, inertial forces dominate over gravitational effects, shifting the primary heat transfer contribution from nucleate to flow boiling. The figure of merit (FOM) confirms the overall performance superiority of the ORM at low mass fluxes. This work provides valuable insights and design guidelines for high-performance, high-aspect-ratio microchannel heat sinks in advanced thermal management systems.