Frost Self-Removal Mechanism during Defrosting on Vertical Superhydrophobic Surfaces: Peeling Off or Jumping Off

Advanced Anti-Icing Strategies and Technologies by Macrostructured Photothermal Storage Superhydrophobic Surfaces

Water is the source of life and civilization, but water icing causes catastrophic damage to human life and diverse industrial processes. Currently, superhydrophobic surfaces (inspired by the lotus effect) aided anti-icing attracts intensive attention due to their energy-free property. Here, recent advances in anti-icing by design and functionalization of superhydrophobic surfaces are reviewed. The mechanisms and advantages of conventional, macrostructured, and photothermal superhydrophobic surfaces are introduced in turn. Conventional superhydrophobic surfaces, as well as macrostructured ones, easily lose the icephobic property under extreme conditions, while photothermal superhydrophobic surfaces strongly rely on solar illumination. To address the above issues, a potentially smart strategy is found by developing macrostructured photothermal storage superhydrophobic (MPSS) surfaces, which integrate the functions of macrostructured superhydrophobic materials, photothermal materials, and phase change materials (PCMs), and are expected to achieve all-day anti-icing in various fields. Finally, the latest achievements in developing MPSS surfaces, showcasing their immense potential, are highlighted. Besides, the perspectives on the future development of MPSS surfaces are provided and the problems that need to be solved in their practical applications are proposed.

Interfacial ice sprouting during salty water droplet freezing

Icing of seawater droplets is capable of causing catastrophic damage to vessels, buildings, and human life, yet it also holds great potential for enhancing applications such as droplet-based freeze desalination and anti-icing of sea sprays. While large-scale sea ice growth has been investigated for decades, the icing features of small salty droplets remain poorly understood. Here, we demonstrate that salty droplet icing is governed by salt rejection-accompanied ice crystal growth, resulting in freezing dynamics different from pure water. Aided by the observation of brine films emerging on top of frozen salty droplets, we propose a universal definition of freezing duration to quantify the icing rate of droplets having varying salt concentrations. Furthermore, we show that the morphology of frozen salty droplets is governed by ice crystals that sprout from the bottom of the brine film. These crystals grow until they pierce the free interface, which we term ice sprouting. We reveal that ice sprouting is controlled by condensation at the brine film free interface, a mechanism validated through molecular dynamics simulations. Our findings shed light on the distinct physics that govern salty droplet icing, knowledge that is essential for the development of related technologies.

Wetting state transitions of individual condensed droplets on pillared textured surfaces

The ability to realize the self-removal of condensed droplets from a surface is of critical importance for science and applications such as water harvesting and thermal engineering. Despite the enormous interest in micro/nanotextured superhydrophobic materials for high-efficiency condensation, a clear picture of the wetting state transition of condensed droplets is missing, particularly, on a single-droplet level of the order of micrometers. Herein, by varying a substantial parameter space of the contact angle and the geometry of the pillared textures, we have quantified the wetting transition of individual droplets during condensation. We found that a droplet is finally either spontaneously removed from the textures due to a Laplace pressure difference or wets the textures; four different wetting state transition modes have been identified numerically and they are classified in a phase diagram. Simple theories have been constructed to correlate the critical conditions of the wetting state transition to the wettability and geometry of the textures, and they were verified experimentally. We found that the self-removal of condensed droplets benefits from the contact angle and the height of the pillars. These findings not only enhance our fundamental understanding of the wetting state transition of condensed droplets but also allow the rational design of micro/nanotextured water-repellent materials for anti-fogging and anti-wetting.

Fabrication of Metallic Superhydrophobic Surfaces with Tunable Condensate Self-Removal Capability and Excellent Anti-Frosting Performance

Laser fabrication of metallic superhydrophobic surfaces (SHSs) for anti-frosting has recently attracted considerable attention. Effective anti-frosting SHSs require the efficient removal of condensed microdroplets through self-propelled droplet jumping, which is strongly influenced by the surface morphology. However, detailed analyses of the condensate self-removal capability of laser-structured surfaces are limited, and guidelines for laser processing parameter control for fabricating rationally structured SHSs for anti-frosting have not yet been established. Herein, a series of nanostructured copper-zinc alloy SHSs are facilely constructed through ultrafast laser processing. The surface morphology can be properly tuned by adjusting the laser processing parameters. The relationship between the surface morphologies and condensate self-removal capability is investigated, and a guideline for laser processing parameterization for fabricating optimal anti-frosting SHSs is established. After 120 min of the frosting test, the optimized surface exhibits less than 70% frost coverage because the remarkably enhanced condensate self-removal capability reduces the water accumulation amount and frost propagation speed (<1 μm/s). Additionally, the material adaptability of the proposed technique is validated by extending this methodology to other metals and metal alloys. This study provides valuable and instructive insights into the design and optimization of metallic anti-frosting SHSs by ultrafast laser processing.

Hydrophilic Slippery Surface Promotes Efficient Defrosting

Frost accretion occurs ubiquitously in various industrial applications and causes tremendous energy and economic loss, as manifested by the Texas power crisis that impacted millions of people over a vast area in 2021. To date, extensive efforts have been made on frost removal by micro-engineering surfaces with superhydrophobicity or lubricity. On such surfaces, air or oil cushions are introduced to suspend the frost layer and promote the rapid frost sliding off, which, although promising, faces the instability of the cushions under extreme frosting conditions. Most existing hydrophilic surfaces, characterized by large interfacial adhesion, have long been deemed unfavorable for frost shedding. Here, we demonstrated that a hydrophilic and slippery surface can achieve efficient defrosting. On such a surface, the hydrophilicity gave rise to a highly interconnected basal frost layer that boosted the substrate-to-frost heat transfer; then, the resulting melted frost readily slid off the surface due to the superb slipperiness. Notably, on our surface, the retained meltwater coverage after frost sliding off was only 2%. In comparison to two control surfaces, for example, surfaces lacking either hydrophilicity or slipperiness, the defrosting efficiency was 13 and 19 times higher and the energy consumption was 2.3 and 6.2 times lower, respectively. Our study highlights the use of a hydrophilic surface for the pronounced defrosting in a broad range of industrial applications.

Using Frost to Promote Cassie Ice on Hydrophilic Pillars

We develop a novel approach to suspend ice in the air-trapping Cassie state without requiring any fragile hydrophobic coatings or nanostructures. First, frost was preferentially grown on the tops of hydrophilic aluminum pillars due to their sharp corners and elevation over the noncondensable gas barrier. Subsequently, Cassie ice was formed by virtue of the impacting droplets getting arrested by the upper frost tips. A scaling model reveals that the dynamic pressure of an impacting droplet causes the water to wick inside the porous frost faster than the timescale to impale between the pillars.

Axial spreading of droplet impact on ridged superhydrophobic surfaces

HYPOTHESIS

Due to the complex hydrodynamics of droplet impact on ridged superhydrophobic surfaces, quantitative droplet spreading characteristics are unrevealed, limiting the practical applications of ridged superhydrophobic surfaces. During droplet impacting, the size ratio (the ratio of the ridge diameter to the droplet diameter) is an important factor that affects droplet spreading dynamics.

EXPERIMENTS

We fabricated ridged superhydrophobic surfaces with size ratios ranging from zero to one, and conduct water droplet impact experiments on these surfaces at varied Weber numbers. Aided by the numerical simulations and theoretical analysis, we illustrate the droplet spreading dynamics and reveal the law on the maximum axial spreading coefficient.

FINDS

The results show that the droplet spreading and retraction dynamics on ridged superhydrophobic surfaces are significantly asymmetric in the axial and spanwise directions. Focusing on the maximum axial spreading coefficient, we find it decreases first and then increases with increasing size ratios, indicating the existence of the critical size ratio. The maximum axial spreading coefficient can be reduced by 25-40% at the critical size ratio compared with that on flat surfaces. To predict the maximum axial spreading coefficient, two theoretical models are proposed respectively for size ratios smaller and larger than the critical size ratio.

Condensation Frosting on Micropillar Surfaces - Effect of Microscale Roughness on Ice Propagation

Microscale surface structures have been widely explored as a promising tool for antifreezing or frost avoidance on heat transfer surfaces. Despite studies of many surface feature designs, the mechanisms associated with condensation freezing and ice propagation on microstructured surfaces have yet to be thoroughly elucidated, espectially when it comes to quantitative understanding. In this work, condensation freezing on circular micropillar surfaces is investigated, with varying pillar spacing and height (layout/microscale roughness) but a constant pillar diameter. The pillar layout is found to have significant effects on both liquid nucleation and neighboring droplet interactions, as reflected by the condensation droplet distribution prior to soilidification and eventually the freezing front propagation area velocity. In general, nucleation is preferred on the pillar top rather than the bottom of the pillared surface unless there is a large distance between the pillars. Interactions between neighboring droplets solely on pillar tops (or bottom surfaces) can induce heterogeneity in the droplet distribution and slow freezing front propagation. Based on the roles the pillars play in nucleation, droplet coalescence, and ice bridging, four different condensation states are identified and related to the layout of the pillars, and the freezing front area propagation velocity is found to be different in each state. The findings provide a quantitative basis for designing antifreezing surfaces, applicable to a wide range of thermal systems.

Departure Velocity of Rolling Droplet Jumping

Droplet jumping phenomenon widely exists in the fields of self-cleaning, antifrosting, and heat transfer enhancement. Numerous studies have been reported on the static droplet jumping while the rolling droplet jumping still remains unnoticed even though it is very common in practice. Here, we used the volume of fluid (VOF) method to simulate the droplet jumping induced by coalescence of a rolling droplet and a stationary one with corresponding experiments conducted to validate the correctness of the simulation model. The departure velocity of the jumping droplet was the main concerned here. The results show that when the center velocity of the rolling droplet (V₀ = ωR, where ω is the angular velocity of the rolling droplet and R is the droplet radius) is fixed, the vertical departure velocity satisfies a power law which can be expressed as V_z,depar = aR^b. When the droplet radius is fixed, the vertical departure velocity first decreases and then increases if the center velocity exceeds a critical value. Interestingly, the critical center velocity is demonstrated to be approximately 0.76 times the capillary-inertial velocity, corresponding to a constant Weber number of 0.58. Different from the vertical departure velocity, the horizontal departure velocity is basically proportional to the center velocity of the rolling droplet. These results deepen the understanding of the droplet jumping physics, which shall further promote related applications in engineering fields.

The Effect of the Initial State of the Droplet Group on the Energy Conversion Efficiency of Self-Propelled Jumping

The essential characteristic of the self-propelled jumping droplet is the jumping velocity, which determines its application value in heat transfer enhancement, antifrosting, self-cleaning, and so on. The jumping velocity is directly related to the energy conversion efficiency (i.e., the ratio of jumping kinetic energy surface energy released by coalescence to surface energy released by coalescence) and it is affected by the initial state of droplets but there is no unified theory to describe the relationship between the initial state of droplets and the energy conversion efficiency. In this paper, the projection of the initial chemical potential and the final chemical potential difference of droplets in the direction of jumping is defined as jumping potential by theoretical analysis of the chemical potential evolution. The effects of droplet number, distribution, and radius ratio on energy conversion efficiency can be synthetically characterized by jumping potential. The larger the jumping potential is, the higher the energy conversion efficiency is. Finally, the rationality and universality of the jumping potential are verified by numerical simulations and comparison with previous studies. The jumping potential can explain phenomena that cannot be explained in previous studies and can provide a synthesis critical value of droplet jumping.

Rapid fabrication of a dual-scale micro-nanostructured superhydrophobic aluminum surface with delayed condensation and ice formation properties

Aluminum (Al) is widely used in all forms of industry, including automobile, aerospace, transmission lines, and exchangers, and in general household appliances. Ice accumulation on Al surfaces may cause serious problems, especially during the winter, leading to critical damage to mechanical systems. In this study, we developed a superhydrophobic coating with anti-icing properties on an Al surface using a simple and cost-effective technique. The superhydrophobic dual-shape micro-/nanostructured (MN-) Al surface was fabricated by a facile chemical etching and an anodization method, followed by surface modification with polydimethylsiloxane (PDMS) via a simple thermal vapor deposition method. The static contact angle of the fabricated surface was more than 160 °C. Compared with the bare surface and the silicone oil-infused PDMS coating (SLIPS) on the MN-structured Al substrate, the fabricated superhydrophobic surface displayed excellent anti-icing. Ice formation on the superhydrophobic surface was delayed by 80 and 45 min at -5 °C and -10 °C, respectively, at a relative humidity of 80% ± 5%. The superhydrophobic surface demonstrated an increase of almost four and two times delay in icing time on the surface over bare and SLIPS surfaces, respectively. The coalescence induced jumping behavior of condensate water droplets was also investigated on the fabricated surfaces. The result indicates that the superhydrophobic surface can effectively delay ice/frost formation by the synergetic effect of surface morphology and the extremely low adhesive property of the surfaces, which allows the self-propelled jumping phenomenon at low temperature and high humidity. This proposed simple, fast, and cost-effective method could be applied to design large-scale anti-icing surfaces.