Direct Metal Forming of a Microdome Structure with a Glassy Carbon Mold for Enhanced Boiling Heat Transfer

The application of microtechnology to traditional mechanical industries is limited owing to the lack of suitable micropatterning technology for durable materials including metal. In this research, a glassy carbon (GC) micromold was applied for the direct metal forming (DMF) of a microstructure on an aluminum (Al) substrate. The GC mold with microdome cavities was prepared by carbonization of a furan precursor, which was replicated from the thermal reflow photoresist master pattern. A microdome array with a diameter of 8.4 μm, a height of ~0.74 μm, and a pitch of 9.9 μm was successfully fabricated on an Al substrate by using DMF at a forming temperature of 645 °C and an applied pressure of 2 MPa. As a practical application of the proposed DMF process, the enhanced boiling heat transfer characteristics of the DMF microdome Al substrate were analyzed. The DMF microdome Al substrate showed 20.4 ± 2.6% higher critical heat flux and 34.1 ± 5.3% higher heat transfer coefficient than those of a bare Al substrate.