Plain Aluminum Research Articles

Mineralogical compositions of soils under three geological formations in some parts of Ogun state, Nigeria and their agricultural potentials

Investigating the mineralogical compositions of soils under different geological formations becomes imperative for maximizing agricultural productivity and ensuring the long-term viability of agricultural practices. Therefore, studies were carried out on mineral compositions and diversities of soils developed over the Basement complex rock, Coastal plain sands and Ewekoro formations in Ogun state Nigeria. A total of nine profile pits (three per location) of 2 m × 1 m × 2 m size were dug in all the three locations. Soil samples were collected from the pedogenic horizons of each profile pits in replicates into a well labeled polyethylene bag. Using X-ray diffractometry (XRD) and scanning electron microscopy (SEM) the mineral contents and their relative abundance, elemental compositions and morphologies of the fine sand, coarse silt and clay fractions of the soils at different topographic positions were identified, described and compared. Results obtained from XRD and SEM analyses exhibited similarities. The most abundant elements in the basement complex and Ewekoro pedon were oxygen, carbon and silicon whereas in the coastal plain sand pedon, oxygen, carbon and aluminum were the most abundant element. The presence of mixed-layer illite, mica, kaolinite, quartz, hematite, anatase, goethite, and chlorite at varying degrees was observed in the pedons developed on these geological formations, although kaolinite and quartz dominated the soil matrix. The mineralogical complexity of the pedons followed the order of basement complex > coastal plain sand > Ewekoro formation. Profiles developed on the Ewekoro formation exhibited the highest degree of weathering, as evidenced by their chemical properties and mineralogical compositions. The petrographic evaluation of the three geological formations revealed that all pedons were rich in quartz and exhibited varying degrees of mineral complexity and maturation. The overlapping and distinct characteristics among the geologies indicated different stages of weathering. By using the mineral maturity index, profiles developed over the basement complex rock and the coastal plain sand could be regarded as sub-matured and this could have contributed significantly to the native fertility of these soils and profiles from the Ewekoro formation were the most weathered. The use of Ewekoro formation for agriculture would necessitate significant investments in agro-inputs and sound principles of soil management through integrated soil fertility management.

Capacitive sensing of frost growth dynamics on aluminum surfaces with different wettabilities

Frost formation is a critical issue in many industries including air conditioning and refrigeration, aviation, transportation, and cryogenics. Frost buildup on heat exchanger surfaces reduces their efficiency by acting as a thermal resistance and by reducing or blocking the airflow. Defrosting is therefore necessary to maintain system efficiency. However, defrost initiation and cycle duration are critical parameters that govern system performance. Excessively early or late defrosting can result in energy loss. Frost detection is thus essential to carry out defrosting efficiently. To know when to initiate defrost, both the density and thickness of the frost must be known as both affect the frost thermal resistance. However, state of the art approaches are not sensitive to both frost density and thickness. Here, a capacitive sensing method is proposed that is sensitive to both the density and thickness of the frost. The method can achieve precise frost detection, offering insights into the ideal time to initiate defrosting by being sensitive to factors that affect frost specific thermal resistance. Experiments are carried out on plain (hydrophilic), superhydrophobic, and superhydrophilic aluminum surfaces at three different surface temperatures (−6 °C, −10 °C, −16 °C) to investigate the sensing performance. The capacitance measured increases with time as frost forms and grows. This change in capacitance, along with mass and thickness data, was used as a tool to characterize frost growth. The results indicate that decreasing wettability (superhydrophilic to plain (hydrophilic) to superhydrophobic) results in a decreasing trend in mass accumulation, frost density, and change in capacitance and an increasing trend in frost thicknesses and thermal resistance. It was also demonstrated that increasing surface temperature results in decreasing changes in capacitance (measurement sensitivity), mass accumulation, frost thicknesses, and thermal resistance, with an increasing trend in frost density. A strong correlation between frost mass and change in capacitance was observed regardless of surface temperature or wettability. This rendered implications for the best time of defrosting initiation. The proposed approach offers high accuracy, sensitivity, and convenience as a non-invasive method to study dynamic frost growth with insights into more optimal defrosting cycles, contributing to the development of more efficient energy systems.

Tribological properties of Al-GNP composites at elevated temperature

Lighter and more powerful next generation vehicles and other rotary machinery demand bearings to operate in harsher conditions for higher efficiency, and the continuous development of advanced low-wear and friction materials is thus becoming even more important to meet these requirements. New aluminium composites reinforced with high performance lubricate phases such as graphene nanoplatelets (GNPs) are very promising and have been vigorously investigated. By maintaining a low coefficient of friction (COF) and offering great strength against wear due to their self-lubricating capability, the solid lubricant like GNPs protect the bearing surface from wear damage and prevent change in metallurgical properties during temperature fluctuations. This paper first studies the high-temperature tribological performance of aluminium matrix composites reinforced with GNP, consolidated via powder metallurgy, then elucidates their tribological mechanism. We report that the best tribological performance is achieved by the composite containing 2.0 wt% GNP, with an extraordinarily low COF of 0.09 and a specific wear rate of 3.5×10−2 mm3·N−1·m−1, which represent 75% and 40% reduction respectively, against the plain aluminium consolidated under identical conditions. The in-track and out-of-track Raman analysis have confirmed the role of GNPs in creating a tribofilm on the counterpart surface which contributed to the excellent performance.

An analysis on CNC machined surface roughness between AA7475 and AA7475/fly ash composite

The present investigation is the influence of limited reinforcement of fly ash (5 wt%) effects on surface roughness. In this regard, the fly Ash reinforced aluminium alloy (AA7475) composite was prepared and machined and measured the surface roughness to compared to aluminium alloy (AA7475). The sample size is 32 (16 for each tool) with 95% CI pre-test power 80% was used. The surface grinding operation is used to remove surface abnormalities. These pieces are machined in specific contour milling and are performed with different tools. Machined specimens are tested using a profilometer for calculating surface roughness and it was performed according to ASTM D3039 standards. The findings suggested that the plain aluminium alloy (AA7475) had a surface roughness of 0.51 mm and the composite aluminium alloy (AA7475) reinforced with 5 wt% fly ash had a surface roughness of 0.38 mm. The statistical value analysis yielded a significance value of 0.034 (p>0.05), indicating that there was substantial variation across the groups. In this research investigation, it was found that the surface roughness of a composite made of a 5 wt% fly ash augmented aluminium alloy (AA7475) was 32.27% lower than that of a plain aluminium alloy.

Enhanced refrigerant flow boiling heat transfer in microstructured finned surfaces

Flow boiling is used in air-conditioning and refrigeration, thermal management of electronics, distillation, chemical synthesis, desalination, power generation, and cryogenics. To enhance the flow boiling heat transfer, internally finned tubing has been widely used. In this work, we demonstrate a fabrication method to generate interal microstructures in 5.2 mm internal diameter finned aluminum tubing through crystallographic chemical etching to further increase heat transfer coefficients of low-GWP refrigerant R-515B. Enhancements in heat transfer coefficients are demonstrated across the range of vapor qualities with peak enhancements up to 172% observed at high vapor qualities with similar levels of enhancements demonstrated with R-134a. The effects of varying operating parameters such as heat flux, mass flux and saturation pressure, on performance improvement were also examined. Flow visualization studies performed through an adiabatic glass visualization section at the test-section exit allowed quantiification of film thickness and showcased lower conduction resistance for microstructured finned surfaces. The advantages of this structuring technique are further highlighted by the relatively minor increase in pressure drop (∼20%). We demostrate that etching of plain aluminum tubes exceeds the performance of finned tubing under high heat flux condtions, with enhancements being more pronounced at low mass fluxes, indicating potential replacement of current extrusion methods used for the manufacture of finned tubing. Surface characterization results after mechanical expansion of the etched finned tubing demonstrated the remenance of microstructures in fin valleys, thus proving potential compatibility with heat exchanger fabrication methods.

A comparative study on CNC contour milling performance of AA7475 with 10 % Fly Ash reinforced novel composite with AA7475 for improving surface finish

This experimental investigation aimed to investigate the machinability of 10 wt.%t Fly Ash reinforced Aluminium Alloy (AA7475) composite and compare with Aluminium Alloy (AA7475) minimize the surface roughness in CNC contour milling of Aluminium alloy, AA7475. The composite was fabricated by the Stir casting method with 90 % of base material AA7475 and 10 % of (Fly Ash) reinforcement material. After the reinforced composite was then cast into a flat plate and further sliced into pieces. The sample size is 32 (16 for each group) with a pretest ‘G’ power setting of 80 %. The prepared samples were machined by CNC contour milling, the samples including both groups such as 10 wt.%t Fly Ash reinforced aluminium alloy (AA7475) composite and aluminium alloy (AA7475). For research, green manufacturing approaches are preferred. Surface roughness testing was carried out by using a Profilometer in all machined specimens. Surface roughness values were obtained for both 10 wt% Fly Ash reinforced aluminium alloy (AA7475) composite and aluminium alloy (AA7475) machined specimens, and T-tests were performed using SPSS. The significance value obtained was 0.04 (p < 0.05). Within the constraints of this study, 10 wt% Fly Ash reinforced aluminium alloy (AA7475) recorded the minimum average surface roughness of 19.48 % in CNC Green Machining in specific contour milling for the reinforced composite (AA7475 + Fly Ash) compared with plain aluminium alloy (AA7475).

Developing Al@GNPs composite coating for pool boiling applications by combining mechanical milling, screen printing and sintering methods

ABSTRACT Due to ever growing ‘demand of the energy’ and for the capability to remove large quantities of heat from the heating surface, pool boiling heat transfer becomes the main attraction for research in search of finding the efficient means for transferring heat. Following this trend, the present study also investigated the pool boiling performance of refrigerants, mainly, pure refrigerant (R-134a) and natural refrigerant (R-600a), on the plain aluminium and two graphene nanoplatelets (GNPs) reinforced aluminium matrix composite (Al@GNPs) coated aluminium heating surface with different thickness (50 ± 5 µm and 125 ± 6 µm), which were synthesised by the help of a three-step technique involving mechanical milling, screen printing and sintering process on the plane aluminium surface. The test is conducted at a saturation temperature of 10°C and heat fluxes ranging from 8.28 kW/m2 to 75.61 kW/m2. Test results of R-134a and R-600a were compared. It is observed that thicker Al@GNPs composite coated surface showed better HTC but with reduced ‘onset of nucleate boiling’ (ONB) wall superheat than the plain Al surface.

Fabrication of aluminum coatings via thermal evaporation technique for enhancement of pool boiling performance of R-600a

In this study, thermal evaporation technique was scrutinized experimentally to fabricate Al coatings on plain aluminum heating surface and improve the pool boiling heat transfer (BHT) performance of R-600a. The Al coatings were fabricated by varying the coating thickness (100 nm, 150 nm, 200 nm and 250 nm). Pool BHT performance of R-600a on a plain aluminum and four Al coated heating surfaces (Al_100 nm, Al_150 nm, Al_200 nm and Al_250 nm) was investigated at a constant saturation temperature of 10 °C. All data were taken at heat fluxes ranging from 9.39 kW/m2 to 74.98 kW/m2. Decrement in the wall superheat was recorded with the increment in the coating thickness, and maximum decrement was observed for the surface with 250 nm thick coating. It was further observed that with the increment of the coating thickness, the HTC of the Al coated heating surfaces was increased than the plain aluminum heating surface. The maximum enhancement in HTC for the Al_250 nm heating surface was 51.62% higher than the plain aluminum heating surface.

Behaviors and Mechanism of Color, COD, and Silica Removals in the Electrocoagulation of Batik Wastewater Using Waste Aluminum Electrodes

Batik wastewater contains organic dyes, waxes, silicate, etc. that are environmentally problematic. Two plain waste aluminum cans were used as electrodes in a batch electrocoagulation (EC) process to remove color, chemical oxygen demand (COD), and silica from batik wastewater. Response surface methodology based on the central composite design was used to demonstrate the dependence of removal efficiency on four key process variables and possible interactions between them. The models were statistically evaluated and conditions for optimized color, COD, and silica removals were verified experimentally. Relatively stronger effects of current density were detected while interactions could be observed on the effects of pH with current density or process time. The floatation of silica scum resulted in increased removal and deviation from the model. The optimal operating conditions were achieved at a current density of 29.91 mA/cm2, an initial pH of 4.51, a reaction time of 24.93 min, and a NaCl dosage of 1.03 g/L that resulted in 88.13 ± 0.51%, 70.50 ± 3.17%, and 100.00 ± 0.00% removals of color, COD, and silica, respectively. The color, COD and pH of the batik wastewater were also reduced to 33 ADMI, 100 mg/L and 6.62 to meet the respective discharge standard limits. Silica content toughened the flocs and increased their buoyancy by strongly interacting with gas bubbles to float to the surface. EC was demonstrated to be an effective and cost-effective treatment technology for the treatment of batik wastewater.

An investigation on ice adhesion and wear of surfaces with differential stiffness

Ice adhesion is known to be higher on stiff metallic surfaces and lower on compliant polymeric surfaces. In designing icephobic surfaces, while one approach is to use surfaces with lower stiffness, such surfaces typically exhibit poor wear resistance. The aim of this study is to create a patterned surface with differential stiffness such that there is always a shared contact between stiff and compliant surfaces, and to study the possibility of such surfaces having an optimal balance between low ice adhesion and favorable wear resistance. Patterned surfaces with alternating layers of stiff aluminum and compliant polyurethane elastomer were fabricated, and ice adhesion and wear behavior of such patterned surfaces are reported. Ice adhesion as a function of the metal-polymer contact area ratio was studied, and patterned surfaces exhibited reduced ice adhesion compared to a plain aluminum surface. Reciprocating ball-on-flat sliding tests were used to study the wear behavior of the surfaces. Wear resistance of the patterned surfaces is presented in terms of wear depth, and the patterned surfaces exhibited higher wear resistance than plain polyurethane surface. Simple finite element modeling was used to arrive at stress states of the patterned surfaces and to understand their wear behavior. The novel surface engineering approach outlined in this paper shows promise for realizing durable icephobic surfaces under contact conditions.

Impact and Bandgap Characteristics of Periodic Rods With Viscoelastic Inserts and Local Resonators

Abstract A comprehensive theoretical and experimental study is presented of the bandgap behavior of periodic viscoelastic material (VEM) composites subjected to impact loading. The composites under consideration consist of an assembly of aluminum sections integrated with periodic inserts which are arranged in one-dimensional configurations. The investigated inserts are manufactured either from VEM only or VEM with local resonators (LR). A finite element model (FEM) is developed to predict the dynamics of this class of VEM composites by integrating the dynamics of the solid aluminum sections with those of VEM using the Golla-Hughes-Mctavish (GHM) mini-oscillator approach. The integrated model enables, for the first time, the accurate predictions of the bandgap characteristics of periodic viscoelastic composites unlike previous studies where the viscoelastic damping is modeled using the complex modulus approach with storage modulus and loss factor are assumed constants and independent of the frequency or the unrealistic and physically inaccurate Kelvin–Voigt viscous-damping models. The predictions of the developed FEM are validated against the predictions of the commercial finite element package ansys. Furthermore, the FEM predictions are checked experimentally using prototypes of the VEM composites with VEM and VEM/LR inserts. Comparisons are also established against the behavior of plain aluminum rods in an attempt to demonstrate the effectiveness of the proposed class of composites in mitigation of the structural response under impact loading. Close agreements are demonstrated between the theoretical predictions and the obtained experimental results.

The Mechanical Properties of Fiber Metal Laminates Based on 3D Printed Composites.

The production and mechanical properties of fiber metal laminates (FMLs) based on 3D printed composites have been investigated in this study. FMLs are structures constituting an alternating arrangement of metal and composite materials that are used in the aerospace sector due to their unique mechanical performance. 3D printing technology in FMLs could allow the production of structures with customized configuration and performance. A series of continuous carbon fiber reinforced composites were printed on a Markforged system and placed between layers of aluminum alloy to manufacture a novel breed of FMLs in this study. These laminates were subjected to tensile, low velocity and high velocity impact tests. The results show that the tensile strength of the FMLs falls between the strength of their constituent materials, while the low and high velocity impact performance of the FMLs is superior to those observed for the plain aluminum and the composite material. This mechanism is related to the energy absorption process displayed by the plastic deformation, and interfacial delamination within the laminates. The present work expects to provide an initial research platform for considering 3D printing in the manufacturing process of hybrid laminates.

Computational study on the potential of aluminium alloy as a candidate material in automotive leaf spring

ABSTRACT Modern advancements and emerging trends in automobile technology have shifted the primary focus of the OEMs to make vehicles lighter, faster, and reliable. Weight has always been a major concern in commercial medium/heavy-duty vehicles. The leaf springs account for 20% of the sprung weight of the vehicle thereby making the suspension system one of the heavy components of an automobile. This paper focuses on analysing the potential of aluminium alloy as a candidate material in leaf spring so as to make the suspension system lighter and more reliable. Aluminium alloy is one of the appropriate materials to proceed with because of its lightweight, strength, and non-significant deformation during load cycles. Three-dimensional CAD model of standard leaf spring was created in DS CATIA V5R19 software and computational analysis were carried out in ANSYS Workbench 18.1 by defining material as plain carbon steel (structural steel) and Aluminium alloy for comparative study. The results of the analysis that the reduction in weight of the leaf spring using aluminium alloy was approximately 64.71% along with a significant reduction in equivalent stress induced at different loading condition with a maximum reduction of 45.30% equivalent stress at the fully loaded dynamic condition.

Wettability-defined frosting dynamics between plane fins in quiescent air

Finned heat exchangers used in energy applications regularly undergo condensation frosting. Understanding the effects of fin spacing on frost growth with surfaces having differing wettability is important for the design of next-generation heat exchangers. This study presents an experimental investigation using high-resolution optical imaging of frost growth between two parallel vertical plain aluminum fins as a function of surface wettability (hydrophilic, superhydrophilic, superhydrophobic), fin surface temperature (-5 to -15 °C), fin spacing (2 to 8 mm), and relative humidity (≈ 50 and 70%). We observe two distinct regimes of frost growth for all test conditions. The effect of surface wettability on frost growth rate becomes significant for fin spacing ≤ 6 mm at fin surface temperatures below -10 °C. The fin surface temperature plays a significant role for fin spacing > 4 mm. Furthermore, for hydrophilic surfaces, the effect of relative humidity was found to be significant for fin spacing > 4 mm. To explain the frosting physics and mass transfer effects, we developed a three-dimensional finite volume method simulation to characterize the moist air flow field between fins at varying fin spacings. For similar humidity, fin surface temperature, and wettability, larger fin spacing resulted in higher frost growth rate due to higher access to moist air. We use the experimental data to develop an empirical correlation for predicting frost thickness. Furthermore, we develop an artificial neural network independent of predetermined functional form that can be trained with the experimental data to predict frost thickness with high accuracy.

Effects of Materials on the Heat Transfer Coefficient During Condensation and Evaporation of R410A

Abstract An experimental investigation was conducted to demonstrate the effects of materials on the heat transfer characteristics of R410A during evaporation and condensation inside two horizontal plain tubes with the same inner diameter of 6 mm, but with two different materials of aluminum and stainless steel. The variation of vapor quality for the test section was kept in the range of 0.2–0.9, while mass velocities were allowed to vary from 100 to 400 kg/m2/s1. First, a series of single-phase and repetitive experiments were conducted to verify the accuracy and reliability of the test rig. Results of the evaporation experiments show that the plain aluminum tube performs best for all tested mass velocities. Several different correlations were employed to predict the present data, and their predictive ability was compared and discussed. Results indicate that the Liu and Winterton correlation could accurately predict the present results except for low mass velocities. Roughness effects were accounted for employing a correction factor. The larger roughness of the stainless steel tube was supposed to make the stainless steel tube perform better if roughness effects were accounted for, so the better performance of the aluminum tube was mainly attributed to the material effects. The pool boiling heat transfer as predicted by the VDI model was compared with the experimental results, and more obvious material effects have been found for pool boiling conditions. The minor differences between the two tubes in this case may be explained by the nucleate boiling suppression and incomplete wetting. For the condensation experiments, little difference was found between the two tested tubes, which means that the material and roughness effects may have had little influence on the thermal performance during condensation.

An Assessment of Mechanical Characteristics of Al 6061 Reinforced with SiC and Bagasse Fly Ash Hybrid MMC

Material is one or more substances that form an object. Due to an attractive mechanical characteristic, materials are commonly selected for structural applications. Recently, the hybrid MMC has been developed and highly an innovative trend in material science. The current study is concentrated on the formation of an innovative hybrid MMC by utilizing aluminum, silicon carbide and fly ash particulates of bagasse. In this study, the physical characteristics of Aluminum 6061 were evaluated by adding Sic, fly ash particulates of bagasse and observed that this is the hardest substance. The compositions were added until the final level and a method of stir casting has been utilized to fabricate Al MMC. XRD ie x-ray diffraction was utilized to analyze the structural characterization of MMC and optical microscopy was utilized to analysis the microstructure on MMC. In this study, the mechanical characteristics like hardness, elongation, yield strength, UTS and density have been performed on MMC. Aluminum was added with 5% of silicon carbide and 10% of fly ash particles of bagasse in one case and in other case aluminum was added with 10% of fly ash particles of bagasse and 10% of silicon carbide. As a result, it was detected that there is an improvement in the hardness and UTS and a reduction in the density and elongation of the composites in comparison to plain aluminum. This shows that the aluminum-silicon carbide-fly ash particles of bagasse MMC substantially differ throughout all characteristics.

Machinability Research on the Micro-Milling for Graphene Nano-Flakes Reinforced Aluminum Alloy

In this paper, plain aluminum was chosen as matrix alloy and graphene reinforced aluminum alloy composites was successfully prepared via powder metallurgy approach. Micro-milling experiments were conducted to explore the effect of varying graphene nanoflakes (GNFs) content (0.5%, 1.0%, and 1.5% by weight) on the machinability of composites and their machining results were compared with that of plain aluminum. Chip morphology, milling force, and machined surface morphology were used as the machinability measures. Experiment results showed that when the content of GNFs is less than 1.5%, the grain refinement of GNFs plays a major role. The hardness and density of the composites are increased. When the content of GNFs is more than 1.5%, the agglomeration phenomenon is obvious, which reduces the hardness and density of the composites. Micro-milling results show that the milling force is the highest when the GNFs content is 1%, and curling degree of chips increased as FPT increase for a certain content of graphene of composites. Furthermore, when the content of GNFs in composites is more than 1%, the surface roughness of milling grooves is greatly improved, which may be related to the lubrication of graphene and the formation of continuous chips.

Mechanical response of the fly ash cenospheres/polyurethane syntactic foams fabricated through infiltration process

Abstract In this paper, the low-cost syntactic foams were prepared by incorporating the fly ash cenospheres into the rigid polyurethane foams. The empirical relations were developed for predicting the porosity of the syntactic foams. Effects of the density and cenospheres size on the mechanical response of both the plain foams and aluminum foils reinforced foams were examined under quasi-static compression. The results show that, when the relative density was below 0.29, the cenospheres size marginally influenced the mechanical properties. When the relative density was above 0.29, the plain foams containing larger cenospheres exhibited better mechanical performances. For the reinforced foams, however, the mechanical properties were significantly improved by using smaller cenospheres. Moreover, the extra mechanical enhancement apart from the addition of the aluminum honeycombs was only effective for the composites containing smaller cenospheres. The reinforcing mechanisms of these composites were identified by the comparison of the mechanical properties and the analysis on their deformation behaviors. It demonstrated that the remarkable reinforcement was dominated by the failure pattern transition in the plain foams. This study may help to develop a comprehensive use of the fly ash cenospheres in civil engineering as functional materials.

Surface wettability effect on nucleate pool boiling heat transfer with titanium oxide (TiO2) coated heating surface

Here, we explored the effect of surface wettability on nucleate pool boiling heat transfer performance by employing hydrophilic titanium oxide (TiO2) layer coated on a cylindrical plain aluminum 6061 (Al 6061) as a reference. The comparative heating surfaces are the plain, TiO2 coated and TiO2-water repellent coated surfaces. The water repellent was superimposed on the reference heater before TiO2 coating on it to depress hydrophilicity nature of TiO2. The boiling tests were carried out in steady-state condition and in saturated water under one atmosphere during the entire experiment. The nucleate boiling performance depends on the level of surface wettability. Results showed that TiO2 coated surface contributed to the increasing of nucleate pool boiling performance by 64.1% in comparison to that of the plain surface. The TiO2-water repellent coated surface gave a less enhanced performance than the TiO2 coated surface, and it is underperformed over the plain surface when the wall superheat (ΔT) > 12.3 °C. Boiling visualization demonstrated the augmented heat transfer mechanism by showing more active nucleation sites and more bubble departure frequency on the TiO2 coated surface.

Enhancement of pool boiling heat transfer in water on aluminum surface with high temperature conductive microporous coating

Abstract The effects of an aluminum high temperature conductive microporous coating (Al-HTCMC) on the nucleate boiling heat transfer (NBHT) coefficient and critical heat flux (CHF) are studied in saturated distilled water at 1 atm. Aluminum powders with three different mean particle diameters (dm = 11, 24, and 66 µm) are used in the fabrication of the Al-HTCMC. For each mean particle diameter, an optimal coating thickness to yield the highest NBHT coefficient is determined. The optimized Al-HTCMC thickness is found to result in comparable NBHT coefficients regardless of the particle diameter. Pool boiling tests with a plain aluminum surface are used for comparison. The coated and plain aluminum surfaces are treated equally before the pool boiling tests to establish a Boehmite oxidation nano layer on the aluminum surfaces. Following the Boehmite treatment, the contact angle is unmeasurable (∼0°) with the Al-HTCMC surface and 12° with a plain aluminum surface. Then, pool boiling tests are performed and reveal comparable CHF (1725–1850 kW/m2) values with or without the Al-HTCMC. However, the Al-HTCMC is shown experimentally to improve the NBHT coefficient by a factor of five as the wall superheat is reduced by from 31 K to 6 K just before CHF. The results obtained are also compared to similar work using an HTCMC layer on a copper surface to demonstrate the performance of the Al-HTCMC.