A multi-physics model-based approach for macro-structured surface design to enhance heat transfer in R410A flash spray cooling systems

Refrigerant flash spray cooling, which offers high heat flux dissipation at low temperatures, holds significant potential for thermal management of high-power electronic devices. While surface structure design can further amplify heat transfer performance, the lack of systematic methodologies to address the complexities of spray cooling has hindered progress. This study establishes a multi-physics computational framework that couples two-phase flash spray dynamics, liquid film heat transfer, and solid heat conduction to systematically optimize macro-structured surfaces. After validating the model against experimental data, the effects of surface geometry (flat, square, straight and pyramid fins) and dimensional parameters on cooling performance were analyzed. The pyramid structure demonstrated superior performance, achieving a 9 K reduction in surface temperature and a 70 % increase in effective heat transfer coefficient compared to the flat surface. Quantitative analysis revealed that optimal macro-structured design hinges on maximizing effective heat transfer area while ensuring uniform liquid film distribution via controlled droplet dynamics. Further parametric studies on nine pyramid geometries identified a base length of 1 mm and height-to-edge ratio of 0.7 as the optimal configuration, balancing heat transfer enhancement and manufacturing costs through a newly proposed Composite Heat Transfer Factor (CHTF). This work provides a mechanistic framework for designing enhanced surfaces in spray cooling systems, bridging critical gaps in both theoretical understanding and engineering application.