An approach for topology optimization of heat sinks for two-phase flow boiling: Part 1 – Model formulation and numerical implementation

Two-phase flow boiling in heat sinks and cold plates is attractive for various thermal management applications due to high effective heat capacity rates and high heat transfer coefficients compared to single-phase operation. In addition, multi-physics topology optimization is sought for generation of high performance thermal management components. Yet, the design of heat sinks using topology optimization has been restricted to single-phase flow physics, due to incompatibility between available two-phase flow models and traditional single-phase topology optimization approaches. Interface-capturing two-phase flow models are too computationally expensive for optimization; mixture and two-fluid models that treat the liquid and vapor phases as an interpenetrating continuum with interfacial transport phenomena captured through empirical correlations are computationally tractable for heat-sink-scale optimization. However, the penalization approaches commonly used to define the structures formed during topology optimization results in arbitrary fin and channel geometries for which a universal two-phase flow correlation is not available. To enable coupling with two-phase mixture models, this work leverages a homogenization approach to topology optimization wherein heat sink designs are represented using spatially varying microstructures with optimized dimensions. A predefined microstructure geometry is chosen for which two-phase flow correlations exist and therefore topology optimization can be performed. This work is the first to develop a topology optimization algorithm using a mixture model for simulating two-phase flow boiling to design heat sinks and cold plates. Part 1 of this study develops and implements the algorithm to investigate topology optimized heat sinks at various heat inputs, topology optimization grid sizes, and maximum vapor quality constraints. Topology optimized heat sinks designed for single-phase versus two-phase flow are compared. There are significant differences in hydraulic and thermal responses of the single-phase and two-phase designs due to high effective heat capacity rates and high heat transfer coefficients of flow boiling. A companion paper (Part 2) focuses on manufacturing, model calibration, and experimental validation of the topology optimized heat sinks under two-phase flow boiling. The algorithm demonstrated in this work extends the capabilities of topology optimization to two-phase flow physics, and thereby enables the design of various two-phase flow components such as evaporators, condensers, heat sinks, and cold plates.