Factors affecting the spontaneous motion of condensate drops on superhydrophobic copper surfaces

Coalescence-Induced Droplet Jumping for Electro-Thermal Sensing

Jumping droplet condensation, whereby microdroplets (ca. 1-100 μm) coalescing on suitably designed superhydrophobic surfaces jump away from the surface, has recently been shown to have a 10× heat transfer enhancement compared to filmwise condensing surfaces. However, accurate measurements of the condensation heat flux remain a challenge due to the need for low supersaturations (<1.1) to avoid flooding. The low corresponding heat fluxes (<5 W/cm2) can result in temperature noise that exceeds the resolution of the measurement devices. Furthermore, difficulties in electro-thermal measurements such as droplet and surface electrostatic charge arise in applications where direct access to the condensing surface, such as in isolated chambers and small integrated devices, is not possible. Here, we present an optical technique that can determine the experimental electro-thermal parameters of the jumping droplet condensation process with high fidelity through the analysis of jumping droplet trajectories. To measure the heat flux, we observed the experimental trajectories of condensate droplets on superhydrophobic nanostructures and simultaneously matched them in space and time with simulated trajectories using the droplet dynamic equations of motion. Two independent approaches yielded mean heat fluxes of approximately 0.13 W/cm2 with standard deviations ranging from 0.047 to 0.095 W/cm2, a 79% reduction in error when compared with classical energy balance-based heat flux measurements. In addition, we analyzed the trajectories of electrostatically interacting droplets during flight and fitted the simulated and experimental results to achieve spatial and temporal agreement. The effect of image charges on a jumping droplet as it approaches the surface was analyzed, and the observed acceleration has been numerically quantified. Our work presents a sensing methodology of electro-thermal parameters governing jumping droplet condensation.

Melting Process of Frozen Sessile Droplets on Superhydrophobic Surfaces

Superhydrophobic surfaces can exhibit icephobicity in many ways due to their large contact angles and small rolling angles. The melting process of frozen droplets on superhydrophobic surfaces is still unclear, hindering the understanding of surface icephobicity. In this experimental study of the melting process of frozen sessile droplets on superhydrophobic surfaces, we find two types of melting morphologies with opposite vortex directions on a single-scale nanostructured (SN) superhydrophobic substrate and a hierarchical-scale micronanostructured (HMN) superhydrophobic substrate. Melting pattern visualizations and flow field measurements showed Marangoni convection and natural convection occurring in the melting sessile droplets. For the HMN superhydrophobic substrate, the internal flow was found to be dominated by Marangoni convection due to the temperature gradient along the surface of the droplet. For the SN superhydrophobic substrate, Marangoni convection was inhibited by the superhydrophobic particles at the surface of the droplet, which were shed from the fragile superhydrophobic substrate during the freezing-melting process, as confirmed by surface characterizations of the substrate and flow measurements of a water pool. These results will help researchers better understand the melting process of frozen droplets and in designing novel icephobic surfaces for numerous applications.

Anti-Condensation Performance of a New Superhydrophobic Coating for Pavements

Superhydrophobic coating ice suppression is an advanced and durable technology that shows great potential for application on pavements. Although many researchers have conducted experimental and theoretical validations to confirm the effectiveness of superhydrophobic surfaces in actively suppressing ice formation, there are still some who remain skeptical. They argue that the roughness of the surface may increase ice adhesion due to the mechanical interlocking effect of condensation droplets in low-temperature and high-humidity environments. In this study, we present a comprehensive investigation of a novel superhydrophobic coating specifically designed for pavement surfaces, aiming to address the question of its active anti-icing/ice-sparing capabilities in a condensing environment. The changes in contact angle before and after condensation for four material surfaces with varying wettability were investigated, as well as the morphology and ice adhesion of liquid water after it freezes on the material surface. The findings reveal that the proposed superhydrophobic coating for pavements effectively prevents condensate droplets from infiltrating the surface structure, resulting in delaying the surface icing time and reducing the attachment strength of the ice.

Superhydrophobic Surface Designing for Efficient Atmospheric Water Harvesting Aided by Intelligent Computer Vision

Atmospheric water harvesting (AWH) is a possible solution for the current water crisis on the Earth, and the key process of AWH has been widely applied in commercial dehumidifiers. To improve the energy efficiency of the AWH process, applying a superhydrophobic surface to trigger coalescence-induced jumping could be a promising technique that has attracted extensive interest. While most previous studies focused on optimizing the geometric parameters such as nanoscale surface roughness (<1 μm) or microscale structures (10 μm to a few hundred μm range), which might enhance AWH, here, we report a simple and low-cost approach for superhydrophobic surface engineering, through alkaline oxidation of copper. The prepared medium-sized microflower structures (3-5 μm) by our method could fill the gap of the conventional nano- and microstructures, simultaneously act as the preferable nucleation sites and the promoter for the condensed droplet mobility including droplet coalescence and departure, and eventually benefit the entire AWH performances. Moreover, our AWH structure has been optimized with the aid of machine learning computer vision techniques for droplet dynamic analysis on a micrometer scale. Overall, the alkaline surface oxidation and medium-scale microstructures could provide excellent opportunities for superhydrophobic surfaces for future AWH.

Preferred Mode of Atmospheric Water Vapor Condensation on Nanoengineered Surfaces: Dropwise or Filmwise?

Condensing atmospheric water vapor on surfaces is a sustainable approach to addressing the potable water crisis. However, despite extensive research, a key question remains: what is the optimal combination of the mode and mechanism of condensation as well as the surface wettability for the best possible water harvesting efficacy? Here, we show how various modes of condensation fare differently in a humid air environment. During condensation from humid air, it is important to note that the thermal resistance across the condensate is nondominant, and the energy transfer is controlled by vapor diffusion across the boundary layer and condensate drainage from the condenser surface. This implies that, unlike condensation from pure steam, filmwise condensation from humid air would exhibit the highest water collection efficiency on superhydrophilic surfaces. To demonstrate this, we measured the condensation rates on different sets of superhydrophilic and superhydrophobic surfaces that were cooled below the dew points using a Peltier cooler. Experiments were performed over a wide range of degrees of subcooling (10-26 °C) and humidity-ratio differences (5-45 g/kg of dry air). Depending upon the thermodynamic parameters, the condensation rate is found to be 57-333% higher on the superhydrophilic surfaces compared to the superhydrophobic ones. The findings of the study dispel ambiguity about the preferred mode of vapor condensation from humid air on wettability-engineered surfaces and lead to the design of efficient atmospheric water harvesting systems.

Not All Sizes of Dust can be Removed by Jumping Condensates on Superhydrophobic Surfaces

It is well known that superhydrophobic surfaces (SHSs) possess self-cleaning ability, either by impacting or rolling water droplets or by self-propelled jumping condensate. However, contaminants that are present in the air are various. Is it possible that these contaminants can all be removed from SHSs by jumping condensate? In this study, hydrophilic SiO₂ micro- or nanoparticles with diameters larger than, comparable to, and smaller than the width of the nanogaps of the SHS were first filled in the nanogaps or suspended on the nanostructures with the help of ethanol, and the resulting SHS was exposed to condensing water vapor. Direct observation through microscopy showed that jumping condensation was still obvious on the SHS that were capped or filled with micro- or nanoparticles. Scanning electron microscopy (SEM) imaging demonstrated that following jumping condensation, particles that possessed diameters significantly smaller or larger than the width of the nanogaps were both removed from the SHS. However, most particles possessing diameters comparable to the width of the nanogaps remained on the SHS. This confirms for the first time that not all contaminants or dust can be removed from an SHS by self-propelled jumping condensate. Furthermore, the study also simply demonstrates that vapor condensation occurs within the nanogaps of the SHS. This study is helpful in further understanding the mechanism of the self-cleaning caused by jumping condensate and exploring the initial formation of condensate droplets on the SHS.

Condensation Heat Transfer Correlation for Micro/Nanostructure Properties of Surfaces

Condensation, which can be observed in nature as a phase change heat transfer phenomenon, is a critical phenomenon in industrial fields such as power generation, water desalination, and environmental control. Many existing studies have applied surfaces with different wettability by controlling the surface topology to enhance condensation heat transfer. However, the industrial applicability is close to zero due to the limited size and shape of surfaces and low supersaturation conditions. Here, we regulate the surface topology of large-area copper tubes, which are representative industrial metals. We fabricated four copper tubes with different surface structures. We analyzed the condensation phenomenon of the modified tube under specific supersaturation conditions by measuring the overall heat transfer coefficient. We analyzed the condensation phenomenon by measuring the condensation heat transfer coefficient. We have recognized that there is a difference between the maximum droplet radius and the droplet detaching frequency depending on the size and shape of the structure. We measured the contact angle and contact angle hysteresis to accurately analyze the droplet behavior on each surface. As a result, we show that there is a correlation between contact angle hysteresis (CAH) and the total heat transfer coefficient, indicating heat transfer performance. These findings can be applied when evaluating surfaces with excellent condensation heat transfer performance for use in real industrial environments, which can dramatically reduce time and cost.

Robust photothermal anti-icing/deicing via flexible CMDSP carbon nanotube films

Photothermal anti-icing/deicing technology is an environmentally friendly surface technology that can be applied to the surface of aircraft, vehicles or ships. However, it is still a huge challenge to develop a strong and stable flexible film that can efficiently convert light to heat. Here, based on a simple electrochemical method to construct a zinc oxide (ZnO) nanoneedles structure on the surface of the carbon nanotube film, a film with the function of condensed micro-droplet self-propelling (CMDSP) was successfully prepared. The prepared film has excellent light absorption capacity and high energy transfer efficiency (76.71%). The film has strong photothermal anti-icing/deicing performance. Under 4406 Lux light irradiation, even under low temperature conditions of -5 °C, the icing delay time exceeds 4 h. This novel characteristic is attributed to the CMDSP function on the surface and the ultra-fast evaporation mechanism, which can remove water droplets on the surface as quickly as possible. This function helps to design energy-saving equipment that requires high-power heating and deicing.

"Anti-Condensation" Aluminum Superhydrophobic Surface by Smaller Nanostructures

According to classical heterogeneous nucleation theory, the free energy barrier (ΔGc) of heterogeneous nucleation of vapor condensation ascends dramatically as the substrate nanostructure diameter (Rs) decreases. Based on this idea, we fabricated two types of superhydrophobic surfaces (SHSs) on an aluminum substrate by different roughening processes and the same fluorization treatment. Water vapor condensation trials by optical microscope and ESEM confirmed that on SHSs with submicron rectangle structures, a typical self-propelled motion of condensates or jumping condensation occurred. However, on SHS with coral-like micro/nano-structures, vapor nucleation occurred tardily, randomly, and sparsely, and the subsequent condensation preferentially occurred on the nuclei formed earlier, e.g., the condensation on such SHS typically followed the Matthew effect. Higher vapor-liquid nucleation energy barrier caused by smaller fluorinated nanostructures should be responsible for such a unique "anti-condensation" property. This study would be helpful in designing new SHSs and moving their application in anti-icing, anti-fogging, air humidity control, and so on.

Mangifera indica Leaf (MIL) as a Novel Material in Atmospheric Water Collection

Here, Mangifera indica leaves (MILs) have been used to collect atmospheric water for the first time. This novel material has been viewed by mankind as environmental waste and is mostly discarded or incinerated, causing environmental pollution. By turning waste into wealth, MILs have proven resourceful and can help ameliorate the water crisis, especially in tropical countries. The unprecedented water collection result is enough to describe MILs as an ideal material for atmospheric water collection when compared to other natural plants. Both the physical and chemical surface morphologies were extensively characterized. This comparative study shows that MIL surface droplet termination and hydrophilic nature differ from those of other materials, with the apex playing a key role in the roll-off of the droplet. The surface wettability and its interaction with the droplet are of keen interest in this study.

Dropwise condensation: From fundamentals of wetting, nucleation, and droplet mobility to performance improvement by advanced functional surfaces

As a ubiquitous vapor-liquid phase-change process, dropwise condensation has attracted tremendous research attention owing to its remarkable efficiency of energy transfer and transformative industrial potential. In recent years, advanced functional surfaces, profiting from great progress in modifying micro/nanoscale features and surface chemistry on surfaces, have led to exciting advances in both heat transfer enhancement and fundamental understanding of dropwise condensation. In this review, we discuss the development of some key components for achieving performance improvement of dropwise condensation, including surface wettability, nucleation, droplet mobility, and growth, and discuss how they can be elaborately controlled as desired using surface design. We also present an overview of dropwise condensation heat transfer enhancement on advanced functional surfaces along with the underlying mechanisms, such as jumping condensation on nanostructured superhydrophobic surfaces, and new condensation characteristics (e.g., Laplace pressure-driven droplet motion, hierarchical condensation, and sucking flow condensation) on hierarchically structured surfaces. Finally, the durability, cost, and scalability of specific functional surfaces are focused on for future industrial applications. The existing challenges, alternative strategies, as well as future perspectives, are essential in the fundamental and applied aspects for the practical implementation of dropwise condensation.

Effect of Surface Structure Complexity on Interfacial Droplet Behavior of Superhydrophobic Titanium Surfaces for Robust Dropwise Condensation

In general, the dropwise condensation supported by superhydrophobic surfaces results in enhanced heat transfer relative to condensation on normal surfaces. However, in supersaturated environments that exceed a certain supersaturation threshold, moisture penetrates the surface structures and results in attached condensation, which reduces the condensation heat transfer efficiency. Therefore, when designing superhydrophobic surfaces for condensers, the surface structure must be resistant to attached condensation in supersaturated conditions. The gap size and complexity of the micro/nanoscale surface structure are the main factors that can be controlled to maintain water repellency in supersaturated environments. In this study, the condensation heat exchange performance was characterized for three different superhydrophobic titanium surface structures via droplet behavior (DB) mapping to evaluate their suitability for power plant condensers. In addition, it was demonstrated that increasing the surface structure complexity increases the versatility of the titanium surfaces by extending the window for improved heat exchange performance. This study demonstrates the usefulness of DB mapping for evaluating the performance of superhydrophobic surfaces regarding their applicability for industrial condenser systems.

Atmospheric Corrosion Protection Performance and Mechanism of Superhydrophobic Surface Based on Coalescence-Induced Droplet Self-Jumping Behavior

The coalescence-induced droplet self-jumping behavior on the superhydrophobic surface (SHS) provides a new way to achieve atmospheric corrosion protection. This work controls the droplet self-jumping behavior by regulating the SHS's surface energy and analyzes the relevant mechanism from the energy perspective, revealing the key pathway by which the surface energy impacts the droplet self-jumping behavior. On this basis, the electrochemical impedance spectroscopy testing technique is used to evaluate the effect of the droplet self-jumping behavior on the SHS corrosion protection performance, and the SHS atmospheric corrosion protection mechanism based on the coalescence-induced droplet self-jumping behavior is revealed. This study provides theoretical guidance for the development of SHS-based anticorrosion protection.

Droplet rolling angle model of micro-nanostructure superhydrophobic coating surface

The droplet rolling angle is one of the important indicators to measure the coating's hydrophobic performance, but the specific factors affecting the droplet rolling angle on the micro-nanostructured superhydrophobic coating surface are not yet known. Based on the rolling mechanism of droplets on rough surfaces, and from the perspective of coating microscopic energy conservation, this paper points out that the micron-scale morphology and the nanoscale morphology can comprehensively affect the droplet rolling angle. From the above perspective, a mathematical model of the droplet rolling angle on the micro-nanostructure superhydrophobic coating surface was established. The model shows that the droplet rolling angle is positively correlated with the ratio of nano-sized pillar width to spacing, the ratio of micron-sized papilla radius to spacing, and the liquid-gas interfacial tension, and is negatively correlated to the droplet intrinsic contact angle, droplet volume and droplet density. The droplet rolling angle calculated by the presented model is in good agreement with the experimentally tested results. This model can provide good accuracy in predicting the droplet rolling angle on the micro-nanostructured superhydrophobic coating surface.

Flexible superhydrophobic surfaces with condensate microdrop self-propelling functionality based on carbon nanotube films

With the development of flexible electronics and wearable devices, there is strong demand for flexible, superhydrophobic, and multifunctional coatings. Motivated by the promise of attractive multifaceted functionality, various techniques have been developed to fabricate flexible surfaces with non-wetting properties. However, until now, there have been few reports on superhydrophobic surfaces with condensate microdrop self-propelling (CMDSP) functionality on a carbon nanotube film. Here, we used a facile electrodeposition method to develop for the first time a new type of flexible superhydrophobic surface with CMDSP functionality based on carbon nanotube films. These flexible CMDSP surfaces are robust after multiple cycles of bending of the film-coated substrate, i.e., without impacting the surface superhydrophobicity and CMDSP performance. The proposed light and flexible surface, combined with CMDSP, will support a novel generation of coatings that are multifunctional, flexible, smart, and energy saving. This new type of functional flexible interface not only opens new avenues in research into the fundamental structure-property relationships of materials, but also exhibits significant application potential for advanced technologies.

Hybrid Hydrophilic-Hydrophobic CuO@TiO2-Coated Copper Mesh for Efficient Water Harvesting

Fresh water scarcity has been a worldwide problem to be solved urgently. Inspired by the outstanding hydrophobic-hydrophilic patterns on the back of Namib desert beetles, hierarchical CuO@TiO₂-coated surface with alternating hydrophilic-hydrophobic chemistry patterns were fabricated utilizing the photocatalysis of titanium dioxide through ultraviolet irradiation. The results indicated that the as-prepared hybrid dual-coated copper mesh enhanced the fog-collection efficiency compared with the uniformly superhydrophobic or superhydrophilic surface. This enhancement can be regulated by controlling the deposition cycle times of TiO₂ multilayers on CuO and UV irradiation time. The best water harvesting behavior was determined at the deposition cycle times of 10 times and UV irradiation time of 4 h. This work findings offer new insights into the fabrication of hybrid hydrophilic-hydrophobic surfaces for highly efficient water harvesting.

Continuous Directional Water Delivery on the 3D-Printed Arrowhead Microstructure Array

Unidirectional transport is attracting increasing attention in the field of microfluidics, because it does not require an external energy supply. However, most of the current self-driving structures are still plagued with persistent problems that restrict their practical applications. These include low transport velocity, short transport distance, and complex structure. This work reports the design of a new arrowhead microstructure array, on which liquid transport can reach speeds of 23 mm/s and the ratio of transport length to channel width (L/R) can reach up to approximately 40. This structure drives liquid through a unique arrow conformation, which can induce capillary force and arrest the reverse motion of the liquid simultaneously. By means of theory, simulation, and experiment, we have studied the mechanism of liquid transport on this structure. We provide a detailed discussion of the relationship between the velocity of liquid transport and the microstructural dimensions. The findings may inspire the design of novel, unidirectional, liquid-spreading surfaces.

Integrative Bioinspired Surface with Wettable Patterns and Gradient for Enhancement of Fog Collection

A novel integrative bioinspired surface with wettable patterns and gradient (WPGS) is proposed for fog collection via a novel anodic oxidation strategy. We study the water collection behaviors on WPGS with different parameters. Quantitative force analysis is presented, providing evidence for the underlying mechanism leading to the directional motion of the droplet, which is consistent with the experimental results. Such a surface can not only improve the fog droplet capture performance effectively owing to wettable patterns but also accelerate surface regeneration by taking full advantage of the cooperation of multidriving forces, leading to a further fog collection enhancement.

Review of Micro–Nanoscale Surface Coatings Application for Sustaining Dropwise Condensation

Condensation occurs in most of the heat transfer processes, ranging from cooling of electronics to heat rejection in power plants. Therefore, any improvement in condensation processes will be reflected in the minimization of global energy consumption, reduction in environmental burdens, and development of sustainable systems. The overall heat transfer coefficient of dropwise condensation (DWC) is higher by several times compared to filmwise condensation (FWC), which is the normal mode in industrial condensers. Thus, it is of utmost importance to obtain sustained DWC for better performance. Stability of DWC depends on surface hydrophobicity, surface free energy, condensate liquid surface tension, contact angle hysteresis, and droplet removal. The required properties for DWC may be achieved by micro–nanoscale surface modification. In this survey, micro–nanoscale coatings such as noble metals, ion implantation, rare earth oxides, lubricant-infused surfaces, polymers, nanostructured surfaces, carbon nanotubes, graphene, and porous coatings have been reviewed and discussed. The surface coating methods, applications, and enhancement potential have been compared with respect to the heat transfer ability, durability, and efficiency. Furthermore, limitations and prevailing challenges for condensation enhancement applications have been consolidated to provide future research guidelines.

Preparation of Colorful, Infrared-Reflective, and Superhydrophobic Polymer Films with Obvious Resistance to Dust Deposition

In recent years, polymer films containing deep color and near-infrared (NIR)-reflective pigments have received much attention for their potential applications in energy-saving fields. However, in practical environments, dust present in the air is easily adsorbed and adheres to the surface of these films, thus gradually reducing their NIR reflectance. In this work, black or deep-red infrared-reflective pigments were firstly mixed with melted low-density polyethylene (LDPE) and then the resulting composite was thermally pressed on to a metal template possessing micro- and nanostructure surface roughness. After being cooled to a suitable temperature, the LDPE composite film was peeled from the template. Ultraviolet-visible-near-infrared spectroscopy and an indoor infrared lamp irradiation test both confirmed that the prepared films exhibit high NIR reflectance and high heat reflectance. Moreover, due to the stretching-controlled micromolding process, the films all exhibited a superhydrophobic (SH) property. After incubation in outdoor conditions for 1 month, the NIR reflectance of the SH films remained almost consistent; however, the films that did not possess SH property showed a marked decrease in their ability to reflect NIR radiation. By a combination of scanning electron microscopy imaging, we conclude that our films are able to resist dust deposition and thus avoid deterioration of their infrared-reflective properties. We believe that these colorful, infrared-reflective, SH, and cost-effective films have potential application for reducing energy consumption where minimal solar irradiation is required.

Effects of wettability on droplet movement in a V-shaped groove

As basic research to understand the behavior of droplets on structured surfaces, we investigated droplet movement in a V-shaped groove while the volume of the droplet changes. We developed a model to explain the mechanism of the droplet movement and the effects of the wettability of the inner walls of the groove on the droplet movement. Furthermore, the model predicted new phenomena and explains the effect of the nonhomogeneous wettability on droplet movement. The predictions of the model match the experimental results well. This research can provide the basic knowledge for manipulating droplets with structured surfaces for various applications.

Enhancement of Coalescence-Induced Nanodroplet Jumping on Superhydrophobic Surfaces

Coalescence-induced droplet self-jumping on superhydrophobic surfaces has received extensive attentions over the past decade because of its potential applications ranging from anti-icing materials to self-sustained condensers, in which a higher jumping velocity v_j is always expected and favorable. However, the previous studies have shown that there is a velocity limit with v_j ≤ 0.23 u_ic for microscale droplets and v_j ≤ 0.127 u_ic for nanoscale droplets, where u_ic is referred to as the inertial-capillary velocity. Here, we show that the jumping velocity can be significantly increased by patterning a single groove, ridge, or more hydrophobic strip, whose size is comparable with the radius of coalescing droplets, on a superhydrophobic surface. We implement molecular dynamics simulations to investigate the coalescence of two equally sized nanodroplets (8.0 nm in radius) on these surfaces. We found that a maximum v_j = 0.23 u_ic is achieved on the surface with a 1.6 nm high and 5.9 nm wide ridge, which is 1.81 times higher than the nanoscale velocity limit. We also demonstrate that the presence of groove, ridge, and strip alters coalescence dynamics of droplets, leading to a significantly shortened coalescence time which remarkably reduces viscous dissipation during coalescence; thus, we believe that the present approach is also effective for microscale droplet jumping.

Recent Progress in Bionic Condensate Microdrop Self-Propelling Surfaces

Bionic condensate microdrop self-propelling (CMDSP) surfaces are attracting increased attention as novel, low-adhesivity superhydrophobic surfaces due to their value in fundamental research and technological innovation, e.g., for enhancing heat transfer, energy-effective antifreezing, and electrostatic energy harvesting. Here, the focus is on recent progress in bionic CMDSP surfaces. Metal-based CMDSP surfaces, which are the most promising in their respective fields, are highlighted for use in future applications. The selected topics are divided into four sections: biological prototypes, mechanism and construction rules, fabrication, and applications of metal-based CMDSP surfaces. Finally, the challenges and future development trends in bionic CMDSP surfaces are envisioned, especially the utilization of potential bionic inspiration in the design of more advanced CMDSP surfaces.

Bioinspired Surfaces with Superwettability for Anti-Icing and Ice-Phobic Application: Concept, Mechanism, and Design

Ice accumulation poses a series of severe issues in daily life. Inspired by the nature, superwettability surfaces have attracted great interests from fundamental research to anti-icing and ice-phobic applications. Here, recently published literature about the mechanism of ice prevention is reviewed, with a focus on the anti-icing and ice-phobic mechanisms, encompassing the behavior of condensate microdrops on the surface, wetting, ice nucleation, and freezing. Then, a detailed account of the innovative fabrication and fundamental research of anti-icing materials with special wettability is summarized with a focus on recent progresses including low-surface energy coatings and liquid-infused layered coatings. Finally, special attention is paid to a discussion about advantages and disadvantages of the technologies, as well as factors that affect the anti-icing and ice-phobic efficiency. Outlooks and the challenges for future development of the anti-icing and ice-phobic technology are presented and discussed.

Enhanced Coalescence-Induced Droplet-Jumping on Nanostructured Superhydrophobic Surfaces in the Absence of Microstructures

Superhydrophobic surfaces are receiving increasing attention due to the enhanced condensation heat transfer, self-cleaning, and anti-icing properties by easing droplet self-removal. Despite the extensive research carried out on this topic, the presence or absence of microstructures on droplet adhesion during condensation has not been fully addressed yet. In this work we, therefore, study the condensation behavior on engineered superhydrophobic copper oxide surfaces with different structural finishes. More specifically, we investigate the coalescence-induced droplet-jumping performance on superhydrophobic surfaces with structures varying from the micro- to the nanoscale. The different structural roughness is possible due to the specific etching parameters adopted during the facile low-cost dual-scale fabrication process. A custom-built optical microscopy setup inside a temperature and relative humidity controlled environmental chamber was used for the experimental observations. By varying the structural roughness, from the micro- to the nanoscale, important differences on the number of droplets involved in the jumps, on the frequency of the jumps, and on the size distribution of the jumping droplets were found. In the absence of microstructures, we report an enhancement of the droplet-jumping performance of small droplets with sizes in the same order of magnitude as the microstructures. Microstructures induce further droplet adhesion, act as a structural barrier for the coalescence between droplets growing on the same microstructure, and cause the droplet angular deviation from the main surface normal. As a consequence, upon coalescence, there is a decrease in the net momentum in the out-of-plane direction, and the jump does not ensue. We demonstrate that the absence of microstructures has therefore a positive impact on the coalescence-induced droplet-jumping of micrometer droplets for antifogging, anti-icing, and condensation heat transfer applications.

Numerical Simulation of Coalescence-Induced Jumping of Multidroplets on Superhydrophobic Surfaces: Initial Droplet Arrangement Effect

The coalescence-induced droplet jumping on superhydrophobic surfaces (SHSs) has attracted considerable attention over the past several years. Most of the studies on droplet jumping mainly focus on two-droplet coalescence events whereas the coalescence of three or more droplets is actually more frequent and still remains poorly understood. In this work, a 3D lattice Boltzmann simulation is carried out to investigate the effect of initial droplet arrangements on the coalescence-induced jumping of three equally sized droplets. Depending on the initial position of droplets on the surface, the droplet coalescence behaviors can be generally classified into two types: one is that all droplets coalesce together instantaneously (concentrated configuration), and the other is that the initial coalesced droplet sweeps up the third droplet in its moving path (spaced configuration). The critical Ohnesorge number, Oh, for the transition of inertial-capillary-dominated coalescence to inertially limited-viscous coalescence is found to be 0.10 for droplet coalescence on SHSs with a contact angle of 160°. The jumping droplet velocity for concentrated multidroplet coalescence at Oh ⩽ 0.10 still follows the inertial-capillary scaling with an increased prefactor, which indicates a viable jumping droplet velocity enhancement scheme. However, the droplet jumping velocity is drastically reduced for the spaced configuration compared to that for the aforementioned concentrated configuration. Because Oh exceeds 0.10, the effects of initial droplet arrangements on multidroplet jumping become weaker as viscosity plays a key role in the merging process. This work will provide effective guidelines for the design of functional SHSs with enhanced droplet jumping for a wide range of industrial applications.

Rough Structure of Electrodeposition as a Template for an Ultrarobust Self-Cleaning Surface

Superhydrophobic surfaces with self-cleaning properties have been developed based on roughness on the micro- and nanometer scales and low-energy surfaces. However, such surfaces are fragile and stop functioning when exposed to oil. Addressing these challenges, here we show an ultrarobust self-cleaning surface fabricated by a process of metal electrodeposition of a rough structure that is subsequently coated with fluorinated metal-oxide nanoparticles. Scanning electron microscopy, Fourier-transform infrared spectroscopy, X-ray photoelectron spectroscopy, and X-ray diffraction were employed to characterize the surfaces. The micro- and nanoscale roughness jointly with the low surface energy imparted by the fluorinated nanoparticles yielded surfaces with water contact angle of 164.1° and a sliding angle of 3.2°. Most interestingly, the surface exhibits fascinating mechanical stability after finger-wipe, knife-scratch, sand abrasion, and sandpaper abrasion tests. It is found that the surface with superamphiphobic properties has excellent repellency toward common corrosive liquids and low-surface-energy substances. Amazingly, the surface exhibited excellent self-cleaning ability and remained intact even after its top layer was exposed to 50 abrasion cycles with sandpaper and oil contamination. It is believed that this simple, unique, and practical method can provide new approaches for effectively solving the stability issue of superhydrophobic surfaces and could extend to a variety of metallic materials.

Delaying Frost Formation by Controlling Surface Chemistry of Carbon Nanotube-Coated Steel Surfaces

Superhydrophobic surfaces are appealing as anti-icing surfaces, given their excellent water repellent performance. However, when water condenses on the surface due to high humidity, the water becomes pinned, and superhydrophobic surfaces fail to perform. Here we studied how the stability of the superhydrophobicity affected water condensation and frost formation. We created rough surfaces with the same surface structure, but with a variety of surface chemistries, and compared their antifrost properties as a function of intrinsic contact angle. Frost initiation was significantly delayed on surfaces with higher intrinsic contact angles. We coupled these macromeasurements with environmental scanning electron microscopy of water droplet initiation under high humidity conditions. These provide experimental evidence toward previous hypotheses that for a lower intrinsic-angle rough surface, Wenzel state is thermodynamically favorable, whereas the higher intrinsic-angle surface maintains a Cassie-Baxter state. Surfaces with a thermodynamically stable Cassie-Baxter state can then act both as antisteam and antifrost surfaces. This research could answer the persistent question of why superhydrophobic surfaces sometimes are not icephobic; anti-icing performance depends on the surface chemistry, which plays a critical role in the stability of the superhydrophobic surfaces.

Large scale generation of micro-droplet array by vapor condensation on mesh screen piece

We developed a novel micro-droplet array system, which is based on the distinct three dimensional mesh screen structure and sintering and oxidation induced thermal-fluid performance. Mesh screen was sintered on a copper substrate by bonding the two components. Non-uniform residue stress is generated along weft wires, with larger stress on weft wire top location than elsewhere. Oxidation of the sintered package forms micro pits with few nanograsses on weft wire top location, due to the stress corrosion mechanism. Nanograsses grow elsewhere to show hydrophobic behavior. Thus, surface-energy-gradient weft wires are formed. Cooling the structure in a wet air environment nucleates water droplets on weft wire top location, which is more "hydrophilic" than elsewhere. Droplet size is well controlled by substrate temperature, air humidity and cooling time. Because warp wires do not contact copper substrate and there is a larger conductive thermal resistance between warp wire and weft wire, warp wires contribute less to condensation but function as supporting structure. The surface energy analysis of drops along weft wires explains why droplet array can be generated on the mesh screen piece. Because the commercial material is used, the droplet system is cost effective and can be used for large scale utilization.

Understanding the Role of Dynamic Wettability for Condensate Microdrop Self-Propelling Based on Designed Superhydrophobic TiO2 Nanostructures

The ability to release the adhered drops on superhydrophobic surfaces is very important for self-cleaning, antifrosting/icing, microfluidic device, and heat transfer applications. In this paper, three types of in situ electrochemical anodizing TiO₂ nanostructure films are rationally designed and fabricated on titanium substrates with special superwettability, viz., TiO₂ nanotube arrays, irregular TiO₂ nanotube arrays, and hierarchical TiO₂ particle arrays (HTPA), and their corresponding behavior in condensate microdrop self-propelling (CMDSP) is investigated. Compared to the flat titanium counterpart, all three types of rough TiO₂ samples demonstrate a uniform distribution of smaller microscale droplets. Among the treated surfaces, the HTPA possesses the highest condensate density, and more than 80% of the droplets possess a diameter below 10 μm. Theoretical analysis indicates that the feature is mainly due to the morphology and structure induced extremely low droplet adhesion on super-antiwetting TiO₂ hierarchical surfaces, where the excess surface energy released from the migration leads to the self-propelling of merged microdrop. This work offers a way to rationally construct CMDSP surfaces with excellent self-cleaning, antifrosting/icing ability, and enhanced condensation heat transfer efficiency.

Capillary-inertial colloidal catapults upon drop coalescence

Surface energy released upon drop coalescence is known to power the self-propelled jumping of liquid droplets on superhydrophobic solid surfaces, and the jumping droplets can additionally carry colloidal payloads toward self-cleaning. Here, we show that drop coalescence on a spherical particle leads to self-propelled launching of the particle from virtually any solid surface. The main prerequisite is an intermediate wettability of the particle, such that the momentum from the capillary-inertial drop coalescence process can be transferred to the particle. By momentum conservation, the launching velocity of the particle-drop complex is proportional to the capillary-inertial velocity based on the drop radius and to the fraction of the liquid mass in the total mass. The capillary-inertial catapult is not only an alternative mechanism for removing colloidal contaminants, but also a useful model system for studying ballistospore launching.

Bioinspired Interfacial Materials with Enhanced Drop Mobility: From Fundamentals to Multifunctional Applications

The development of bioinspired interfacial materials with enhanced drop mobility that mimic the innate functionalities of nature will have a significant impact on the energy, environment and global healthcare. Despite extensive progress, state of the art interfacial materials have not reached the level of maturity sufficient for industrial applications in terms of scalability, stability, and reliability. These are complicated by their operating environments and lack of facile approaches to control the local structural texture and chemical composition at multiple length scales. The recent advances in the fundamental understanding are reviewed, as well as practical applications of bioinspired interfacial materials, with an emphasis on the drop bouncing and coalescence-induced jumping behaviors. Perspectives on how to catalyze new discoveries and to foster technological adoption to move this exciting area forward are also suggested.

Design and fabrication of clustered rugged ZnO nanotube films with condensate microdrop self-propelling function

We design and fabricate a type of condensate microdrop self-propelling (CMDSP) clustered rugged nanotube film, which is achieved by two-step electrodeposition and low-surface-energy silane modification.

Fabrication of copper-based ZnO nanopencil arrays with high-efficiency dropwise condensation heat transfer performance

A copper-based zinc oxide nanopencil array film was reported. Compared with hydrophobic flat Cu surface, it exhibits condensate microdrop self-propelling function and maximal ∼140% enhancement in dropwise condensation heat transfer coefficient.

Enhanced Jumping-Droplet Departure

Water vapor condensation on superhydrophobic surfaces has received much attention in recent years because of its ability to shed water droplets at length scales 3 decades smaller than the capillary length (∼1 mm) via coalescence-induced droplet jumping. Jumping-droplet condensation has been demonstrated to enhance heat transfer, anti-icing, and self-cleaning efficiency and is governed by the theoretical inertial-capillary scaled jumping speed (U). When two droplets coalesce, the experimentally measured jumping speed (Uexp) is fundamentally limited by the internal fluid dynamics during the coalescence process (Uexp < 0.23U). Here, we theoretically and experimentally demonstrate multidroplet (>2) coalescence as an avenue to break the two-droplet speed limit. Using side-view and top-view high-speed imaging to study more than 1000 jumping events on a copper oxide nanostructured superhydrophobic surface, we verify that droplet jumping occurs as a result of three fundamentally different mechanisms: (1) coalescence between two droplets, (2) coalescence among more than two droplets (multidroplet), and (3) coalescence between one or more droplets on the surface and a returning droplet that has already departed (multihop). We measured droplet-jumping speeds for a wide range of droplet radii (5-50 μm) and demonstrated that while the two-droplet capillary-to-inertial energy conversion mechanism is not identical to that of multidroplet jumping, speeds above the theoretical two-droplet limit (>0.23U) can be achieved. However, we discovered that multihop coalescence resulted in drastically reduced jumping speeds (≪0.23U) due to adverse momentum contributions from returning droplets. To quantify the impact of enhanced jumping speed on heat-transfer performance, we developed a condensation critical heat flux model to show that modest jumping speed enhancements of 50% using multidroplet jumping can enhance performance by up to 40%. Our results provide a starting point for the design of enhanced-performance jumping-droplet surfaces for industrial applications.

Subcooled-Water Nonstickiness of Condensate Microdrop Self-Propelling Nanosurfaces

We report perfect humidity-tolerant subcooled-water nonstickiness on condensate microdrop self-propelling (CMDSP) surfaces. As exemplified by a CMDSP nanoneedle surface, we find that impinged subcooled drops can instantly rebound and simultaneously take away surface condensate. Remarkably, continuously poured subcooled water can also shed off on the nanosample surface. In sharp contrast, they instantly freeze on the contrast flat hydrophobic surface. Such a superior performance may be ascribed to nanostructure-induced extremely low solid-liquid interface adhesion and prevention of phase transition from the liquid subcooled water to the solid ice. These findings help in the development of low-adhesive superhydrophobic surfaces suitable for a cold and humid environment.

Hierarchical Nanoflowers on Nanograss Structure for a Non-wettable Surface and a SERS Substrate

Hierarchical nanostructures of CuO nanoflowers on nanograss were investigated for self-cleaning and surface plasmonic applications. We achieved the hierarchical nanostructures using one-step oxidation process by controlling the formation of flower-like nanoscale residues (nanoflowers) on CuO nanograss. While the nanograss structure of CuO has a sufficient roughness for superhydrophobic characteristics, the additional hierarchy of nanoflowers on nanograss leads to a semi-reentrant structure with a high repellency even for a very small droplet (10 nL) of low surface tension liquid such as 25 % ethanol (~35 mN/m), thus providing non-wettable and self-cleaning properties. Furthermore, the CuO hierarchical nanostructure serves as a substrate for surface-enhanced Raman spectroscopy (SERS). Both of the CuO nanograss and nanoflower provide many nanoscale gaps that act as hot-spots for surface-enhanced Raman signal of 4-mercaptopyridine (4-Mpy), thus enabling a non-destructive detection in a short analysis time with relatively simple preparation of sample. Especially, the CuO nanoflower has larger number of hot-spots at the nanogaps from floral leaf-like structures, thus leading to three times higher Raman intensity than the CuO nanograss. These multifunctional results potentially provide a path toward cost-effective fabrication of a non-wettable surface for self-maintenance applications and a SERS substrate for sensing applications.

Design and Fabrication of a Hybrid Superhydrophobic-Hydrophilic Surface That Exhibits Stable Dropwise Condensation

Condensation of water vapor is an essential process in power generation, water collection, and thermal management. Dropwise condensation, where condensed droplets are removed from the surface before coalescing into a film, has been shown to increase the heat transfer efficiency and water collection ability of many surfaces. Numerous efforts have been made to create surfaces which can promote dropwise condensation, including superhydrophobic surfaces on which water droplets are highly mobile. However, the challenge with using such surfaces in condensing environments is that hydrophobic coatings can degrade and/or water droplets on superhydrophobic surfaces transition from the mobile Cassie to the wetted Wenzel state over time and condensation shifts to a less-effective filmwise mechanism. To meet the need for a heat-transfer surface that can maintain stable dropwise condensation, we designed and fabricated a hybrid superhydrophobic-hydrophilic surface. An array of hydrophilic needles, thermally connected to a heat sink, was forced through a robust superhydrophobic polymer film. Condensation occurs preferentially on the needle surface due to differences in wettability and temperature. As the droplet grows, the liquid drop on the needle remains in the Cassie state and does not wet the underlying superhydrophobic surface. The water collection rate on this surface was studied using different surface tilt angles, needle array pitch values, and needle heights. Water condensation rates on the hybrid surface were shown to be 4 times greater than for a planar copper surface and twice as large for silanized silicon or superhydrophobic surfaces without hydrophilic features. A convection-conduction heat transfer model was developed; predicted water condensation rates were in good agreement with experimental observations. This type of hybrid superhydrophobic-hydrophilic surface with a larger array of needles is low-cost, robust, and scalable and so could be used for heat transfer and water collection applications.

Facile Fabrication of Anodic Alumina Rod-Capped Nanopore Films with Condensate Microdrop Self-Propelling Function

We report that aluminum surfaces can be endowed with condensate microdrop self-propelling (CMDSP) function by one-step voltage-rising mild anodization in hot phosphoric acid solution followed by fluorosilane modification. Via regulating reaction parameters, we can achieve anodic alumina self-standing rod-capped nanopore films and minimize their solid-liquid interface adhesion. Such low-adhesive nanostructured film owns remarkable CMDSP function, especially to condensate microdrops with sizes below 50 μm, differing from usual gravity-driven dropwise condensation on flat aluminum surfaces. Clearly, this work offers a facile, efficient, and industry-compatible approach to processing CMDSP aluminum materials, which is significant for developing innovative energy-saving air-conditioner heat exchangers.

A Comprehensive Model of Electric-Field-Enhanced Jumping-Droplet Condensation on Superhydrophobic Surfaces

Superhydrophobic micro/nanostructured surfaces for dropwise condensation have recently received significant attention due to their potential to enhance heat transfer performance by shedding positively charged water droplets via coalescence-induced droplet jumping at length scales below the capillary length and allowing the use of external electric fields to enhance droplet removal and heat transfer, in what has been termed electric-field-enhanced (EFE) jumping-droplet condensation. However, achieving optimal EFE conditions for enhanced heat transfer requires capturing the details of transport processes that is currently lacking. While a comprehensive model has been developed for condensation on micro/nanostructured surfaces, it cannot be applied for EFE condensation due to the dynamic droplet-vapor-electric field interactions. In this work, we developed a comprehensive physical model for EFE condensation on superhydrophobic surfaces by incorporating individual droplet motion, electrode geometry, jumping frequency, field strength, and condensate vapor-flow dynamics. As a first step toward our model, we simulated jumping droplet motion with no external electric field and validated our theoretical droplet trajectories to experimentally obtained trajectories, showing excellent temporal and spatial agreement. We then incorporated the external electric field into our model and considered the effects of jumping droplet size, electrode size and geometry, condensation heat flux, and droplet jumping direction. Our model suggests that smaller jumping droplet sizes and condensation heat fluxes require less work input to be removed by the external fields. Furthermore, the results suggest that EFE electrodes can be optimized such that the work input is minimized depending on the condensation heat flux. To analyze overall efficiency, we defined an incremental coefficient of performance and showed that it is very high (∼10(6)) for EFE condensation. We finally proposed mechanisms for condensate collection which would ensure continuous operation of the EFE system and which can scalably be applied to industrial condensers. This work provides a comprehensive physical model of the EFE condensation process and offers guidelines for the design of EFE systems to maximize heat transfer.

Copper-Based Ultrathin Nickel Nanocone Films with High-Efficiency Dropwise Condensation Heat Transfer Performance

We report a type of copper-based ultrathin nickel nanocone films with high-efficiency dropwise condensation heat transfer (DCHT) performance, which can be fabricated by facile electrodeposition and low-surface-energy chemistry modification. Compared with flat copper samples, our nanosamples show condensate microdrop self-propelling (CMDSP) function and over 89% enhancement in the DCHT coefficient. Such remarkable enhancement may be ascribed to the cooperation of surface nanostructure-induced CMDSP function as well as in situ integration and ultrathin nature of nanofilms. These findings are very significant to design and develop advanced DCHT materials and devices, which help improve the efficiency of thermal management and energy utilization.

Condensate microdrop self-propelling aluminum surfaces based on controllable fabrication of alumina rod-capped nanopores

Here, we report a type of aluminum-based condensate microdrop self-propelling (CMDSP) functional films based on the controllable fabrication of anodic alumina rod-capped nanopores, which can be realized by a three-step method based on the skillful combinations of well-established hard anodization, mild anodization and chemical etching techniques. Such a surface nanoengineering strategy is verified to be feasible via our exemplified experiments and scanning electronic microscopy characterizations. After fluorosilane modification, the surface nanostructure can induce the efficient self-jumping of small-scale condensate microdrops, especially below 50 μm. This work offers an avenue for developing CMDSP aluminum surfaces with self-cleaning, antifrosting, and antidewing functions.

Departure of condensation droplets on superhydrophobic surfaces

This article focuses on the departure of multidroplet coalescence on a superhydrophobic surface with nanoscale roughness. Out-of-plane jumping events triggered by multidroplet coalescence and a single fallen droplet are observed. Experimental data show that the departure of droplets due to the multidroplets coalescence and the jumping modes is dominant for the removal of condensed droplets from the substrate. The energy barrier is easier to overcome and the critical size of the self-propelled droplets could be further decreased in multidroplet coalescence jumping mode. A general theoretical model is developed which accounts quantitatively for determining the jumping velocity and the critical size of the multidroplet coalescence.

Fabrication of condensate microdrop self-propelling porous films of cerium oxide nanoparticles on copper surfaces

Condensate microdrop self-propelling (CMDSP) surfaces have attracted intensive interest. However, it is still challenging to form metal-based CMDSP surfaces. We design and fabricate a type of copper-based CMDSP porous nanoparticle film. An electrodeposition method based on control over the preferential crystal growth of isotropic nanoparticles and synergistic utilization of tiny hydrogen bubbles as pore-making templates is adopted for the in situ growth of cerium oxide porous nanoparticle films on copper surfaces. After characterizing their microscopic morphology, crystal structure and surface chemistry, we explore their CMDSP properties. The nanostructure can realize the efficient ejection of condensate microdrops with sizes below 50 μm.