Decoupled Hierarchical Structures for Suppression of Leidenfrost Phenomenon

Understanding and Utilizing Droplet Impact on Superhydrophobic Surfaces: Phenomena, Mechanisms, Regulations, Applications, and Beyond

Droplet impact is a ubiquitous liquid behavior that closely tied to human life and production, making indispensable impacts on the big world. Nature-inspired superhydrophobic surfaces provide a powerful platform for regulating droplet impact dynamics. The collision between classic phenomena of droplet impact and the advanced manufacture of superhydrophobic surfaces is lighting up the future. Accurately understanding, predicting, and tailoring droplet dynamic behaviors on superhydrophobic surfaces are progressive steps to integrate the droplet impact into versatile applications and further improve the efficiency. In this review, the progress on phenomena, mechanisms, regulations, and applications of droplet impact on superhydrophobic surfaces, bridging the gap between droplet impact, superhydrophobic surfaces, and engineering applications are comprehensively summarized. It is highlighted that droplet contact and rebound are two focal points, and their fundamentals and dynamic regulations on elaborately designed superhydrophobic surfaces are discussed in detail. For the first time, diverse applications are classified into four categories according to the requirements for droplet contact and rebound. The remaining challenges are also pointed out and future directions to trigger subsequent research on droplet impact from both scientific and applied perspectives are outlined. The review is expected to provide a general framework for understanding and utilizing droplet impact.

Inhibiting the Leidenfrost Effect by Superhydrophilic Nickel Foams with Ultrafast Droplet Permeation

Inhibiting the Leidenfrost effect has drawn extensive attention due to its detrimental impact on heat dissipation in high-temperature industrial applications. Although hierarchical structures have improved the Leidenfrost point to over 1000 °C, the current performance of single-scale structures remains inadequate. Herein, we present a facile high-temperature treatment method to fabricate superhydrophilic nickel foams that demonstrate ultrafast droplet permeation within tens of milliseconds, elevating the Leidenfrost point above 500 °C. Theoretical analysis based on the pressure balance suggests that these remarkable features arise from the superhydrophilic property, high porosity, and large pore diameter of nickel foams that promote capillary wicking and vapor evacuation. Compared to solid nickel surfaces with a Leidenfrost temperature of approximately 235 °C, nickel foams nucleate boiling at high superheat, triggering an order of magnitude higher heat flux. The effects of the pore diameter and surface temperature on droplet permeation behaviors and heat transfer characteristics are also elucidated. The results indicate that droplet permeation is dominated by inertial and capillary forces at low and high superheat, respectively, and moderate pore diameters are more conducive to facilitating droplet permeation. Furthermore, our heat transfer model reveals that pore diameter plays a negligible role in the heat flux at high surface temperatures due to the trade-off between effective thermal conductivity and specific surface area. This work provides a new strategy to address the Leidenfrost effect by metal foams, which may promise great potential in steel forging and nuclear reactor safety.

Dynamic Behavior of Droplet Impact on Laminar Superheated Particles

The impact of droplets on particles involves a wide range of complex phenomena and mechanisms, including bubble nucleation, crater formation, fluidization, and more intricate changes in the boiling regime when impacting superheated particles. In this study, we focus on droplet impact behavior on superheated laminar particles at various temperatures and define six typical characteristic patterns of a single droplet impact on superheated laminar particles, including film evaporation, bubbly boiling, immersion boiling, sputter boiling, transition boiling, and film boiling. It is worth noting that the variations of inertial force FI caused by gravity, the capillary force FC generated by the pores of the droplets, and the dewetting force by the vapor phase FV are the main contributors to different evaporation regimes. Interestingly, we find that the Leidenfrost point (LFP) of droplets on the laminar superheated particles decreases with particle size, which is related to the effect of the pore space generated between the laminar particles. Finally, the effect of temperature, particle size, and Weber number (We) on the dynamic behavior of droplet impact is revealed. Experimental results show that the instantaneous diameter of droplets is inversely proportional to the change of height, with different patterns of maximum spreading diameter and maximum bounce height at different particle sizes, while the maximum spreading velocity and maximum bounce velocity are independent of particle size. We believe the present work would provide a broader knowledge and comprehension of the droplet impact on heated particles and promote the development of the safety and productivity of industrial processes such as fluid catalytic cracking, spray drying, and spray cooling.

Delayed Leidenfrost Effect of a Cutting Droplet on a Microgrooved Tool Surface

Regulation over the generation of the Leidenfrost phenomenon in liquids is vitally important in a cutting fluid/tool system, with benefits ranging from optimizing the heat transfer efficiency to improving the machining performance. However, realizing the influence mechanism of liquid boiling at various temperatures still faces enormous challenges. Herein, we report a kind of microgrooved tool surface by laser ablation, which could obviously increase both the static and dynamic Leidenfrost point of cutting fluid by adjusting the surface roughness (Sa). The physical mechanism that delays the Leidenfrost effect is primarily due to the ability of the designed microgroove surface to store and release vapor during droplet boiling so that the heated surface requires higher temperatures to generate sufficient vapor to suspend the droplet. We also find six typical impact regimes of cutting fluid under various contact temperatures; it is worth noting that Sa has a great influence on the transform threshold among six impact regimes, and the likelihood that a droplet will enter the Leidenfrost regime decreases with increasing Sa. In addition, the synergistic effect of Sa and tool temperature on the droplet kinetics of cutting droplets is investigated, and the relationship between the maximum rebound height and the dynamic Leidenfrost point is correlated for the first time. Significantly, cooling experiments on the heated microgrooved surface are performed and demonstrate that it is effective to improve the heat dissipation ability of cutting fluid by delaying the Leidenfrost effect on the microgrooved heated surface.

Tailoring vapor film beneath a Leidenfrost drop

For a drop on a very hot solid surface, a vapor film will form beneath the drop, which has been discovered by Leidenfrost in 1756. The vapor escaping from the Leidenfrost film causes uncontrollable flows, and actuates the drop to move around. Recently, although numerous strategies have been used to regulate the Leidenfrost vapor, the understanding of surface chemistry for modulating the phase-change vapor dynamics remains incomplete. Here, we report how to rectify vapor by "cutting" the Leidenfrost film using chemically heterogeneous surfaces. We demonstrate that the segmented film cut by a Z-shaped pattern can spin a drop, since the superhydrophilic region directly contacts the drop and vaporizes the water, while a vapor film is formed on the superhydrophobic surrounding to jet vapor and reduce heat transfer. Furthermore, we reveal the general principle between the pattern symmetry design and the drop dynamics. This finding provides new insights into the Leidenfrost dynamics modulation, and opens a promising avenue for vapor-driven miniature devices.

Enhancing Boiling Heat Transfer on a Superheated Surface by Surfactant-Laden Droplets

Boiling, one of the most common phase-change heat transfer methods, is widely used in nuclear power plants, spacecraft, integrated circuits, and other situations, where rapid and efficient heat transfer is crucial. However, boiling heat transfer is efficient only in a specific surface temperature range when a droplet impacts a superheated surface. Here, we enhance the boiling heat transfer and extend this temperature range by adding a tiny amount of surfactant. We find that surfactants can weaken the Kelvin effect of boiling bubbles, and thus reduce the onset of boiling driven temperature and significantly enhance the maximum vaporization rate of the droplet effectively. In particular, different from previous studies, we find that the surfactants at lower concentrations can increase the Leidenfrost temperature of the droplets. All the above effects jointly expand the temperature range of effective boiling heat transfer. This study sheds new light on the role of surfactants in the boiling process and offers a new medium to promote heat-transfer applications.

Reducing Contact Time of Droplets Impacting Superheated Hydrophobic Surfaces

Reducing the contact time (t_c ) of a droplet impacting a solid surface is crucial in various fields. Superhydrophobic (SHB) surfaces are used to reduce t_c at room temperature. However, at high temperatures, SHB surfaces cannot achieve t_c reduction because of the failure of the coating materials or the Leidenfrost (LF) effect. Therefore, a surface that can suppress the LF effect and reduce t_c at high temperatures is required. To create such a surface, a double-reentrant groove (DRG) array surface with an overhanging structure on top of the microgrooves is developed. The overhanging structure renders the surface hydrophobic (HB). Despite its HB nature, the DRG surface's LF point (LFP) is observed at ≈530 °C, which is higher than the LFP on other HB surfaces. Moreover, a t_c smaller than the inertia-capillary limit on the DRG surface is observed at between 400 and 500 °C. Accordingly, the DRG surface is currently the only HB surface for t_c reduction at high temperatures. The DRG surface avoids the limitation of low LFPs observed on HB surfaces. Due to its HB properties, the DRG surface is determined to exhibit self-cleaning characteristics and can be used in various applications at high temperatures.

Inhibiting the Leidenfrost effect above 1,000 °C for sustained thermal cooling

The Leidenfrost effect, namely the levitation of drops on hot solids¹, is known to deteriorate heat transfer at high temperature². The Leidenfrost point can be elevated by texturing materials to favour the solid-liquid contact^2-10 and by arranging channels at the surface to decouple the wetting phenomena from the vapour dynamics³. However, maximizing both the Leidenfrost point and thermal cooling across a wide range of temperatures can be mutually exclusive^3,7,8. Here we report a rational design of structured thermal armours that inhibit the Leidenfrost effect up to 1,150 °C, that is, 600 °C more than previously attained, yet preserving heat transfer. Our design consists of steel pillars serving as thermal bridges, an embedded insulating membrane that wicks and spreads the liquid and U-shaped channels for vapour evacuation. The coexistence of materials with contrasting thermal and geometrical properties cooperatively transforms normally uniform temperatures into non-uniform ones, generates lateral wicking at all temperatures and enhances thermal cooling. Structured thermal armours are limited only by their melting point, rather than by a failure in the design. The material can be made flexible, and thus attached to substrates otherwise challenging to structure. Our strategy holds the potential to enable the implementation of efficient water cooling at ultra-high solid temperatures, which is, to date, an uncharted property.

Effect of Surface Textures and Wettability on Droplet Impact on a Heated Surface

A liquid droplet can hover over a solid surface that is heated above the Leidenfrost point (LFP), at which an insulating vapor layer is formed that acts as a heat transfer barrier. Recent studies have reported that hierarchical micro- and nanoscale textures provide high wettability and significant LFP enhancement. However, such textures are often difficult and expensive to fabricate. Therefore, this study aimed to experimentally demonstrate LFP enhancement through the use of low-cost hierarchical textures. Surface textures were fabricated by coating SiO2 nanoparticles on stainless steel wire meshes. The droplet lifetime method was used to determine the LFP in a temperature range of 200 °C–490 °C. High-speed imaging (4000–23,000 fps) was performed for visualizing the impact behavior of a droplet. The LFP value of the nanocoated mesh surface was found to be greater than 490 °C. This enhanced LFP was 178 °C higher than that of a stainless steel surface and 38 °C higher than that of a single-layer textured surface. Furthermore, with respect to the LFP enhancement, the explosive impact behavior of a droplet can be observed on nanocoated mesh surfaces.

Transport Phenomena in Nano/Molecular Confinements

The transport of fluid and ions in nano/molecular confinements is the governing physics of a myriad of embodiments in nature and technology including human physiology, plants, energy modules, water collection and treatment systems, chemical processes, materials synthesis, and medicine. At nano/molecular scales, the confinement dimension approaches the molecular size and the transport characteristics deviates significantly from that at macro/micro scales. A thorough understanding of physics of transport at these scales and associated fluid properties is undoubtedly critical for future technologies. This compressive review provides an elaborate picture on the promising future applications of nano/molecular transport, highlights experimental and simulation metrologies to probe and comprehend this transport phenomenon, discusses the physics of fluid transport, tunable flow by orders of magnitude, and gating mechanisms at these scales, and lists the advancement in the fabrication methodologies to turn these transport concepts into reality. Properties such as chain-like liquid transport, confined gas transport, surface charge-driven ion transport, physical/chemical ion gates, and ion diodes will provide avenues to devise technologies with enhanced performance inaccessible through macro/micro systems. This review aims to provide a consolidated body of knowledge to accelerate innovation and breakthrough in the above fields.

Film levitation and central jet of droplet impact on nanotube surface at superheated conditions

Influences of surface nanotubes at high temperatures are investigated on droplet impact dynamics and Leidenfrost effect. Five distinct regimes of impact droplets are found on the nanotube surface, including contact boiling, film levitation, central jet levitation, central jet, and Leidenfrost phenomenon. The regimes of film levitation, central jet levitation, and central jet are characterized by either film levitation and/or liquid central jet. The regime of Leidenfrost phenomenon is characterized by droplet bounce-off behavior free of any liquid jets. Film levitation is driven by the vaporization of two parts of the droplet, with one as the droplet bottom layer over the contact area above the nanotube structure, and the other as the hemiwicking liquid in nanotubes. Both the vaporization is impaired by increasing the surface temperature, which is attributed to the reduced contact time and less extent of spread of the droplet at a higher surface temperature. The central jet phenomenon is driven by the vapor stream produced by hemiwicking liquid in the central area upon impact. It is enhanced and then suppressed by elevating the surface temperature, resulting from the collective effects of the vapor pressure in nanotubes which increases with the surface temperature, and the cross-sectional area of the vapor stream, which increases and then decreases with the surface temperature. At a high Weber number, the Leidenfrost temperature can be increased by 125^{∘}C on the nanotube surface, implying a great potential in heat transfer enhancement for droplet-based applications.

Partial Leidenfrost Evaporation-Assisted Ultrasensitive Surface-Enhanced Raman Spectroscopy in a Janus Water Droplet on Hierarchical Plasmonic Micro-/Nanostructures

The conventional methods of creating superhydrophobic surface-enhanced Raman spectroscopy (SERS) devices are by conformally coating a nanolayer of hydrophobic materials on micro-/nanostructured plasmonic substrates. However, the hydrophobic coating may partially block hot spots and therefore compromise Raman signals of analytes. In this paper, we report a partial Leidenfrost evaporation-assisted approach for ultrasensitive SERS detection of low-concentration analytes in water droplets on hierarchical plasmonic micro-/nanostructures, which are fabricated by integrating nanolaminated metal nanoantennas on carbon nanotube (CNT)-decorated Si micropillar arrays. In comparison with natural evaporation, partial Leidenfrost-assisted evaporation on the hierarchical surfaces can provide a levitating force to maintain the water-based analyte droplet in the Cassie-Wenzel hybrid state, i.e., a Janus droplet. By overcoming the diffusion limit in SERS measurements, the continuous shrinking circumferential rim of the droplet, which is in the Cassie state, toward the pinned central region of the droplet, which is in the Wenzel state, results in a fast concentration of dilute analyte molecules on a significantly reduced footprint within several minutes. Here, we demonstrate that a partial Leidenfrost droplet on the hierarchical plasmonic surfaces can reduce the final deposition footprint of analytes by 3-4 orders of magnitude and enable SERS detection of nanomolar analytes (10^-9 M) in an aqueous solution. In particular, this type of hierarchical plasmonic surface has densely packed plasmonic hot spots with SERS enhancement factors (EFs) exceeding 10⁷. Partial Leidenfrost evaporation-assisted SERS sensing on hierarchical plasmonic micro-/nanostructures provides a fast and ultrasensitive biochemical detection strategy without the need for additional surface modifications and chemical treatments.

On interfacial viscosity in nanochannels

Capillary driven transport of liquids in nanoscopic channels is an omnipresent phenomenon in nature and technology including fluid flow in the human body and plants, drug delivery, nanofluidic devices, and energy/water systems. However, the kinetics of this mass transport mechanism remains in question as the well-known Lucas-Washburn (LW) model predicts significantly faster flow rates compared to the experimental observations. We here showed the role of interfacial viscosity in capillary motion slowdown in nanochannels through a combination of experimental, analytical and molecular dynamics techniques. We showed that the slower liquid flow is due to the formation of a thin liquid layer adjacent to the channel walls with a viscosity substantially greater than the bulk liquid. By incorporating the effect of the interfacial layer, we presented a theoretical model that accurately predicts the capillarity kinetics in nanochannels of different heights. Non-equilibrium molecular dynamics simulation confirmed the obtained interfacial viscosities. The viscosities of isopropanol and ethanol within the interfacial layer were 9.048 mPa s and 4.405 mPa s, respectively (i.e. 279% and 276% greater than their bulk values). We also showed that the interfacial layers are 6.4 nm- and 5.3 nm-thick for isopropanol and ethanol, respectively.

Rectification of Mobile Leidenfrost Droplets by Planar Ratchets

The self-transportation of mobile Leidenfrost droplets with well-defined direction and velocity on millimetric ratchets is one of the most representative and spectacular phenomena in droplet dynamics. Despite extensive progress in the ability to control the spatiotemporal propagation of droplets, it remains elusive how the individual ratchet units, as well as the interactions within their arrays, are translated into the collective droplet dynamics. Here, simple planar ratchets characterized by uniform height normal to the surface are designed. It is revealed that on planar ratchets, the transport dynamics of Leidenfrost droplets is dependent not only on individual units, but also on the elegant coordination within their arrays dictated by their topography. The design of planar ratchets enriches the fundamental understanding of how the surface topography is translated into dynamic and collective droplet transport behaviors, and also imparts higher applicability in microelectromechanical system based fluidic devices.

Can Wicking Control Droplet Cooling?

Wicking, defined as absorption and passive spreading of liquid into a porous medium, has been identified as a key mechanism to enhance the heat transfer and prevent the thermal crisis. Reducing the evaporation time and increasing the Leidenfrost point (LFP) are important for an efficient and safe design of thermal management applications, such as electronics, nuclear, and aeronautics industry. Here, we report the effect of the wicking of superhydrophilic nanowires (NWs) on the droplet vaporization from low temperatures to temperatures above the Leidenfrost transition. By tuning the wicking capability of the surface, we show that the most wickable NW results in the fastest evaporation time (reduction of 82, 76, and 68% compared with a bare surface at, respectively, 51, 69, and 92 °C) and in one of the highest shifts of the LFP of a water droplet (5 μL) in the literature (about 260 °C).

Ultrahigh Evaporative Heat Fluxes in Nanoconfined Geometries

Advancement in high-performance photonics/electronics devices has boosted generated thermal energy, making thermal management a bottleneck for accelerated innovation in these disciplines. Although various methods have been used to tackle the thermal management problem, evaporation with nanometer fluid thickness is one of the most promising approaches for future technological demands. Here, we studied thin-film evaporation in nanochannels under absolute negative pressure in both transient and steady-state conditions. We demonstrated that thin-film evaporation in nanochannels can be a bubble-free process even at temperatures higher than boiling temperature, providing high reliability in thermal management systems. To achieve this bubble-free characteristic, the dimension of nanochannels should be smaller than the critical nucleolus dimension. In transient evaporative conditions, there is a plateau in the velocity of liquid in the nanochannels, which limits the evaporative heat flux. This limit is imposed by liquid viscous dissipation in the moving evaporative meniscus. In contrast, in steady-state condition, unprecedented average interfacial heat flux of 11 ± 2 kW cm^-2 is achieved in the nanochannels, which corresponds to liquid velocity of 0.204 m s^-1. This ultrahigh heat flux is demonstrated for a long period of time. The vapor outward transport from the interface is both advective and diffusion controlled. The momentum transport of liquid to the interface is the limiting physics of evaporation at steady state. The developed concept and platform provide a rational route to design thermal management technologies for high-performance electronic systems.

Acoustic detection of electrostatic suppression of the Leidenfrost state

At high temperatures, a droplet can rest on a cushion of its vapor (the Leidenfrost effect). Application of an electric field across the vapor gap fundamentally eliminates the Leidenfrost state by attracting liquid towards the surface. This study uses acoustic signature tracking to study electrostatic suppression of the Leidenfrost state on solid and liquid surfaces. It is seen that the liquid-vapor instabilities that characterize suppression on solid surfaces can be detected acoustically. This can be the basis for objective measurements of the threshold voltage and frequency required for suppression. Acoustic analysis provides additional physical insights that would be challenging to obtain with other measurements. On liquid surfaces, the absence of an acoustic signal indicates a different suppression mechanism (instead of instabilities). Acoustic signature tracking can also detect various boiling patterns associated with electrostatically assisted quenching. Overall, this work highlights the benefits of acoustics as a tool to better understand electrostatic suppression of the Leidenfrost state, and the resulting heat transfer enhancement.

Electrostatic Suppression of the Leidenfrost State on Liquid Substrates

An applied electric field can fundamentally eliminate the Leidenfrost effect (formation of a vapor layer at the solid-liquid interface at high temperatures). This study analyzes electrostatic suppression of the Leidenfrost state on liquid substrates. Electrostatic suppression on silicone oil and Wood's metal (liquid alloy) is studied via experimentation, high-speed imaging, and analyses. It is seen that the nature of electrostatic suppression can be drastically different from that on a solid substrate. First, the Leidenfrost droplet completely penetrates into the silicone oil substrate and converts to a thin film under an electric field. This is due to the existence of an electric field inside the substrate and the deformability of the silicone oil interface. A completely different type of suppression is observed for Wood's metal and solid substrates, which have low deformability and lack an electric field in the substrate. Second, the minimum voltage to trigger suppression is significantly lower on silicone oil when compared to Wood's metal and solid substrates. Fundamental differences between these transitions are analyzed, and a multiphysics analytical model is developed to predict the vapor layer thickness on deformable liquids. Overall, this study lays the foundation for further studies on electrostatic manipulation of the Leidenfrost state on liquids.