Dependences of Formation and Transition of the Surface Condensation Mode on Wettability and Temperature Difference

Uniform and Persistent Jumping Detachment of Condensed Nanodroplets

Realizing jumping detachment of condensed droplets from solid surfaces at the smallest sizes possible is vital for applications such as antifogging/frosting and heat transfer. For instance, if droplets uniformly jump at sizes smaller than visible light wavelengths of 400-720 nm, antifogging issues could be resolved. In comparison, the smallest droplets experimentally observed so far to jump uniformly were around 16 μm in radius. Here, we show molecular dynamics (MD) simulations of persistent droplet jumping with a uniform radius down to only 3.6 nm on superhydrophobic thin-walled lattice (TWL) nanostructures integrated with superhydrophilic nanospots. The size cutoff is attributed to the preferential cross-lattice coalescence of island droplets. As an application, the MD results exhibit a 10× boost in the heat transfer coefficient (HTC), showing a -1 scaling law with the maximum droplet radius. We provide phase diagrams for jumping and wetting behaviors to guide the design of lattice structures with advanced antidew performance.

Enrichment Effects Induced by Non-uniform Wettability Surfaces in the Presence of Non-condensable Gas: A Molecular Dynamics Simulation

For vapor condensation, the control of heterogeneous nucleation and spatial distribution of nuclei are crucial for regulating droplet dynamics and improving condensation efficiency. However, due to the complex characteristics of multicomponent, multiphase, and multiscale, the underlying mechanism of mixed vapor condensation remains unclear, especially at the nucleation stage. In this paper, we focus on the enrichment effects of non-uniform wettability surfaces by molecular dynamics simulation, which could intensify the droplet nucleation and growth processes in a water-air mixed system. The results clarify the inhibitory effect of non-condensable gas on droplet nucleation and prove that only 1% of non-condensable gas could reduce one half of the condensation performance from a molecular perspective. Furthermore, non-uniform surfaces are designed to promote the efficient enrichment of vapor molecules on nucleation sites, and the synergistic effect of hydrophilic and hydrophobic regions is proposed. In addition, the non-uniform wettability surfaces are characterized by varying the proportion and dispersion of hydrophilic regions. The results reveal that an optimal proportion of hydrophilic region (R = 5/6) could furnish the non-uniform surface with the best transfer performance. Moreover, the enhancement of condensation performance can also be achieved through the dispersed arrangement of hydrophilic regions. The results provide guidance for the optimized design of functionalized surfaces with enhanced mixed vapor condensation.

Formation of Liquid Film in Heterogeneous Condensation of Water Vapor: Effects of Solid-Fluid Interaction and Sulfuric Acid Component

Understanding the phenomenon of filmwise condensation on solid surfaces is vital for industrial processes such as air pollutant control and desalination. In this work, we study the formation of condensed liquid films via molecular dynamics simulations, and the effects of solid-fluid interactions and the sulfuric acid component are given major attention. Water is chosen as the fluid, while the solid-fluid interaction is modified to characterize different solid surfaces. The results show that as the solid-fluid interaction decreases, the solid surface transforms from a completely wetting surface to a partially wetting surface, and the film formation process shows significant differences. The condensed liquid on the completely wetting surface forms small liquid films, which merge to form a complete film covering the surface. With the enhancement of solid-fluid interaction, the condensation rate increases first and then remains virtually invariant, resulting in a film formation time that decreases first and then maintains constant. The condensed liquid on the partially wetting surfaces appears as nanodroplets, and the coalescence between nanodroplets leads to the formation of the liquid film. It is found that the stronger the solid-fluid interaction, the more the coalesced droplets tend to be pinned at nucleation sites, the easier it is to form a liquid film, and the shorter the time required for droplet merging. The sulfuric acid component accelerates liquid film formation on both completely wetting and partially wetting surfaces, but the effect of sulfuric acid is more significant on partially wetting surfaces. The 5% molar fraction of sulfuric acid reduces the nucleation time by 72% and increases the condensation rate by 137% under partial wetting, while the same amount of sulfuric acid only increases the nucleation rate by 6% on the completely wetting surface.

Nanoscale Thin-Film Boiling Processes on Heterogeneous Surfaces

Acquiring rapid and efficient boiling processes has been the focus of industry as they have the potential to improve the energy efficiency and reduce the carbon emissions of production processes. Here, we report nanoscale thin-film boiling on different heterogeneous surfaces. Through nonequilibrium molecular dynamics simulation, we captured the triple-phase interface details, visualized the bubble nucleation, and recorded the internal fluid flow and thermal characteristics. It is found that nanoscale thin-film boiling without the occurrence of bubble nucleation shows excellent heat and mass transfer performance, which differs from macroscale boiling. In general, rough structures advance the onset time of stable boiling and improve the efficiency. The heat transfer coefficient and heat flux on a rough hydrophilic surface respectively reach to 7.43 × 10⁴ kW/(m²·K) and 1.3 × 10⁶ kW/m² at a surface temperature of 500 K, which are 100-fold higher than those of micrometer-scale thin-film boiling. However, due to the resultant vapor film trapped between the liquid and the surface, the rough hydrophobic surface leads to heat transfer deterioration instead. It is revealed that the underlying mechanism of regulatory effects resulting from surface physicochemical properties is originated from the variation of interfacial thermal resistance. It is available to reduce the overall interfacial resistance and further improve the heat and mass transfer efficiency through increasing surface roughness, enhancing surface wettability, and increasing the area proportion of the hydrophilic region. This work provides guidelines to achieve rapid and efficient thin-liquid-film boiling and serves as a reference for the optimized design of surfaces utilized for high-heat flux removal through vaporization processes.

Flow Condensation Heat Transfer Characteristics of Nanochannels with Nanopillars: A Molecular Dynamics Study

Flow condensation in nanochannels is a high-efficiency method to deal with increasingly higher heat flux from micro/nanoelectronic devices. Here, we study the flow condensation heat transfer characteristics of nanochannels with different nanopillar cross-sectional areas and heights using molecular dynamics simulation. Results show that two phases containing vapor in the middle of the channel and liquid near walls can be distinguished by obvious interfaces when the fluid is at a stable state. The condensation performance can be promoted by adding nanopillars. With the increase in nanopillar cross-sectional areas or heights, the time that the fluid spends to reach stability will be put off, while the condensation performance enhances. Different from the small enhancement of nanopillar cross-sectional areas, the condensation heat transfer performance improves significantly at a higher nanopillar height, which increases the heat transfer rates by 11.6 and 35.8% when heights are 6a and 8a, respectively. The preeminent condensation heat transfer performance is ascribed to the fact that nanopillars with a higher height disturb the vapor-liquid interface and vapor region, which not only allows vapor atoms with strong Brownian motion to collide with nanopillar atoms directly but also increases deviations of vapor-liquid potential energy to facilitate condensation heat transfer in nanochannels.

Stable and Efficient Nanofilm Pure Evaporation on Nanopillar Surfaces

Molecular dynamics simulations were conducted to systematically investigate how to maintain and enhance nanofilm pure evaporation on nanopillar surfaces. First, the dynamics of the evaporation meniscus and the onset and evolution of nanobubbles on nanopillar surfaces were characterized. The meniscus can be pinned at the top surface of the nanopillars during evaporation for perfectly wetting fluid. The curvature of the meniscus close to nanopillars varies dramatically. Nanobubbles do not originate from the solid surface, where there is an ultrathin nonevaporation film due to strong solid-fluid interaction, but originate and evolve from the corner of nanopillars, where there is a quick increase in potential energy of the fluid. Second, according to a parametric study, the smaller pitch between nanopillars (P) and larger diameter of nanopillars (D) are found to enhance evaporation but also raise the possibility of boiling, whereas the smaller height of nanopillars (H) is found to enhance evaporation and suppress boiling. Finally, it is revealed that the nanofilm thickness should be maintained beyond a threshold, which is 20 Å in this work, to avoid the suppression effect of disjoining pressure on evaporation. Moreover, it is revealed that whether the evaporative heat transfer is enhanced on the nanopillar surface compared with the smooth surface is also affected by the nanofilm thickness. The value of nanofilm thickness should be determined by the competition between the suppression effect on evaporation due to the decrease in the volume of supplied fluid and the existence of capillary pressure and the enhancement effect on evaporation due to the increase in the heating area. Our work serves as the guidelines to achieve stable and efficient nanofilm pure evaporative heat transfer on nanopillar surfaces.

Preferential Vapor Nucleation on Hierarchical Tapered Nanowire Bunches

Controlling vapor nucleation on micro-/nanostructured surfaces is critical to achieving exciting droplet dynamics and condensation enhancement. However, the underlying mechanism of nucleation phenomena remains unclear because of its nature of nanoscale and transience, especially for the complex-structured surfaces. Manipulating vapor nucleation via the rational surface design of micro-/nanostructures is extremely challenging. Here, we fabricate hierarchical surfaces comprising tapered nanowire bunches and crisscross microgrooves. Nanosteps are formed around the top of the nanowire bunches, where the nanowires all around agglomerate densely because of surface tension. The theoretical analysis and molecular dynamics simulation show that nanostep morphologies that are around the top of the nanowire bunches can enable a lower energy barrier and a higher nucleation capability than those of the sparsely packed nanowires at the center and bottom of the nanowire bunches. Vapor condensation experiments demonstrate that the nucleation preferentially occurs around the top of the nanowire bunches. The results provide guidelines to design micro-/nanostructures for promoting vapor nucleation and droplet removal in condensation.