Nanoengineering Scalephobic Surfaces for Liquid Cooling Enhancement

Crystallization fouling, a process where mineral scales form on surfaces, is of broad importance in nature and technology, negatively impacting water treatment and electricity production. However, a rational methodology for designing materials with intrinsic resistance to scaling and scale adhesion remains elusive. Here, guided by nucleation physics, this work investigates the effect of coating composition and surface structure on the nucleation and growth mechanism of scale on metallic heat transfer surfaces nanoengineered by large-area techniques. This work observes that on hydrophilic nanostructured copper, despite its significantly enlarged surface area compared to smooth surfaces, scale formation is substantially suppressed leading to sustained, efficient cooling performance. This work reveals the mechanism through thermofluidic modeling coupled with in situ optical characterization and show that surface bubble formation through degassing is responsible for generating local hot spots enhancing supersaturation. This work then demonstrates a scalephobic nanostructured surface which reduces the accumulated surface scale mass 3.5× and maintains an 82% higher heat transfer coefficient compared to superhydrophobic surfaces with corresponding energy conversion savings. This work not only advances the understanding of fouling mechanisms but also holds promise for practical applications in industries reliant on efficient heat transfer processes.