Micro-/Nanoscale Approach for Studying Scale Formation and Developing Scale-Resistant Surfaces

Dynamics of Snowflakes Impacting Superhydrophobic Surfaces

Snow and ice accumulation on surfaces presents significant safety and efficiency challenges across various industries, necessitating the development of effective mitigation strategies. In this study, the dynamics and energy dissipation of natural snowflakes impacting superhydrophobic surfaces (SHS) were explored using high-speed imaging and a novel image processing method. The size, velocity (impact and bounce), and contact time of natural wet snowflakes were quantitatively analyzed, identifying two primary impact outcomes: bouncing and fragmentation. The analysis focused on bouncing to study the coefficient of restitution (COR) of snowflakes. It was found that small snowflakes (<1.40 mm in diameter) with low impact velocities (<2.90 m/s) tend to be bounced, whereas larger, faster snowflakes are more likely to be fragmented. For the first time, the contact time of natural snowflakes on SHS was also reported, introducing a dimensionless contact time (DCT) for quantifying energy dissipation during the impact. The results indicate that energy dissipation has a cubic relationship with snowflake size and a quadratic relationship with its impact velocity, demonstrating that larger and faster snowflakes dissipate more energy. It is observed that a reduction in DCT leads to an exponential increase in COR and a decrease in normalized energy dissipation, supporting the theoretical prediction that the COR approaches one and the normalized energy dissipation approaches zero as the DCT approaches zero. These results are significant for enhancing the design and efficiency of anti-icing surfaces, contributing to the development of models that simulate snow accumulation behaviors and inform better design of both active and passive snow mitigation strategies.

Nanostructured Surfaces Enhance Nucleation Rate of Calcium Carbonate

Nucleation and growth of calcium carbonate on surfaces is of broad importance in nature and technology, being essential to the calcification of organisms, while negatively impacting energy conversion through crystallization fouling, also called scale formation. Previous work studied how confinements, surface energies, and functionalizations affect nucleation and polymorph formation, with surface-water interactions and ion mobility playing important roles. However, the influence of surface nanostructures with nanocurvature-through pit and bump morphologies-on scale formation is unknown, limiting the development of scalephobic surfaces. Here, it is shown that nanoengineered surfaces enhance the nucleation rate by orders of magnitude, despite expected inhibition through effects like induced lattice strain through surface nanocurvature. Interfacial and holographic microscopy is used to quantify crystallite growth and find that nanoengineered interfaces experience slower individual growth rates while collectively the surface has 18% more deposited mass. Reconstructions through nanoscale cross-section imaging of surfaces coupled with classical nucleation theory-utilizing local nanocurvature effects-show the collective enhancement of nano-pits.

Imparting scalephobicity with rational microtexturing of soft materials

Crystallization fouling, a process where scale forms on surfaces, is widespread in nature and technology, negatively affecting energy and water industries. Despite the effort, rationally designed surfaces that are intrinsically resistant to it remain elusive, due in part to a lack of understanding of how microfoulants deposit and adhere in dynamic aqueous environments. Here, we show that rational tuning of coating compliance and wettability works synergistically with microtexture to enhance microfoulant repellency, characterized by low adhesion and high removal efficiency of numerous individual microparticles and tenacious crystallites in a flowing water environment. We study the microfoulant interfacial dynamics in situ using a micro-scanning fluid dynamic gauge system, elucidate the removal mechanisms, and rationalize the behavior with a shear adhesive moment model. We then demonstrate a rationally developed coating that can remove 98% of deposits under shear flow conditions, 66% better than rigid substrates.

Generality of Evaporative Crystal Liftoff on Heated Hydrophobic Substrates

Scaling or mineral fouling occurs due to the presence of dissolved minerals in water. Scaling is problematic in numerous industrial and household plumbing applications where water is used. The current methods of scale removal often utilize harsh chemicals that are not environmentally friendly. The evaporation of a saline droplet provides a platform to study the role of the substrate in the dynamics of crystallization during scaling. In the present work, we show out-of-plane growth of crystal deposits during the evaporation of saline droplets of aqueous potassium chloride on a heated smooth and microtextured hydrophobic substrate. These out-of-plane deposits, termed as "crystal legs", are in minimal contact with the substrate and can be easily removed from the substrate. The out-of-plane evaporative crystallization of saline droplets of different initial volumes and concentrations is observed irrespective of the chemistry of the hydrophobic coating and the crystal habits investigated. We attribute this general behavior of crystal legs to the growth and stacking of smaller crystals (size ∼10 μm) between the primary crystals toward the end of evaporation. We show that the rate at which the crystal legs grow increases with an increase in the substrate temperature. A mass conservation model is applied to predict the leg growth rate, which agrees well with the experiments.

Sustainable scale resistance on a bioinspired synergistic microspine coating with a collectible liquid barrier

Scale deposition, especially in the petroleum industry, has always been a serious issue because of its potential safety hazards and huge economic cost. However, conventional scale-resistant strategies based on mechanical descaling and chemical detergents can't feed the urgent demand for energy saving and environmental protection. Herein, we report a bioinspired long-term oil collectible mask (BLOCK)-a microspine coating with the synergistic effect of anti-adhesion and oil collection, displaying sustainable scale resistance towards oilfield-produced water. Inspired by pitcher plants, the oil layer as a liquid barrier inhibits scale deposition by changing the underwater scaling micro-environment from liquid/solid/solid to a liquid/solid/liquid triphase system. Oil droplets are collected by cacti-inspired microspines to enhance oil layer stability. Compared with stainless steel, the BLOCK coating shows ca. 98% reduction even after 35 days in artificial produced water. This strategy could be utilized to design integrated functional materials for conquering complex environments such as oil recovery and transportation.

Sulfate mineral scaling: From fundamental mechanisms to control strategies

Sulfate scaling, as insoluble inorganic sulfate deposits, can cause serious operational problems in various industries, such as blockage of membrane pores and subsurface media and impairment of equipment functionality. There is limited article to bridge sulfate formation mechanisms with field scaling control practice. This article reviews the molecular-level interfacial reactions and thermodynamic basis controlling homogeneous and heterogeneous sulfate mineral nucleation and growth through classical and non-classical pathways. Common sulfate scaling control strategies were also reviewed, including pretreatment, chemical inhibition and surface modification. Furthermore, efforts were made to link the fundamental theories with industrial scale control practices. Effects of common inhibitors on different steps of sulfate formation pathways (i.e., ion pair and cluster formation, nucleation, and growth) were thoroughly discussed. Surface modifications to industrial facilities and membrane units were clarified as controlling either the deposition of homogeneous precipitates or the heterogeneous nucleation. Future research directions in terms of optimizing sulfate chemical inhibitor design and improving surface modifications are also discussed. This article aims to keep the readers abreast of the latest development in mechanistic understanding and control strategies of sulfate scale formation and to bridge knowledge developed in interfacial chemistry with engineering practice.

Materials, Preparation Strategies, and Wearable Sensor Applications of Conductive Fibers: A Review

The recent advances in wearable sensors and intelligent human-machine interfaces have sparked a great many interests in conductive fibers owing to their high conductivity, light weight, good flexibility, and durability. As one of the most impressive materials for wearable sensors, conductive fibers can be made from a variety of raw sources via diverse preparation strategies. Herein, to offer a comprehensive understanding of conductive fibers, we present an overview of the recent progress in the materials, the preparation strategies, and the wearable sensor applications related. Firstly, the three types of conductive fibers, including metal-based, carbon-based, and polymer-based, are summarized in terms of their principal material composition. Then, various preparation strategies of conductive fibers are established. Next, the primary wearable sensors made of conductive fibers are illustrated in detail. Finally, a robust outlook on conductive fibers and their wearable sensor applications are addressed.

Effects of Solid Precipitation and Surface Corrosion on the Adhesion Strengths of Sintered Hydrate Deposits on Pipe Walls

A hydrate directly growing and sintering on a pipe wall is an important hydrate deposition case that has been relatively unexplored. In the present study, the adhesion strengths of a sintered cyclopentane (CyC5) hydrate deposit under different solid precipitation and surface corrosion conditions were measured and discussed. It was found that the hydrate adhesion strengths increased by 1.2-1.5× when the soaking time of the carbon steel substrate in a 5 wt % NaCl solution increased from 24 to 72 h, which reduced the water wetting angle from 112 ± 3.5° to 94 ± 3.3°. The wax coating reduced the strength of CyC5 hydrate adhesion by up to nearly 20-fold by reversing the substrate wettability and affecting the hydrate morphology. The measurements performed on scales indicate that calcium carbonate scales strengthen the adhesion strength because of the decrease in the water wetting angle. In addition, honeycomb holes on the surface reduce amplification. Furthermore, settling quartz sand on the wall reduced the adhesion strengths by decreasing the effective sintering area of the hydrate on the underlying base. Finer sand and higher concentrations led to lower strengths. On the basis of the verified linear correlation between the hydrate adhesion strength and the adhesion work of droplets on different substrates and the influence of water conversion during deposition, both an equation and a key constant parameter were obtained to predict the sintered hydrate deposit adhesion strengths on substrates.

Scale-Phobic Surfaces Made of Rare Earth Oxide Ceramics

Scaling or precipitation fouling involves crystallization of hard and chalky solid salts from a solution. Scaling results in significant production and energy losses and is a major concern in many industries. Here we investigate the scale-phobicity of rare earth oxide (REO) ceramics (particularly CeO₂, Gd₂O₃, and Er₂O₃) in comparison with glass and stain-less steel. We quantify the surface energy and its polar and apolar components for these materials using the Van Oss-Chaudhury-Good approach and show a direct correlation between surface energy and scale deposition. We also show that the polar component of surface energy is the main contributor to scale deposition; hence, REOs with minimal polar component represent high barrier to scale deposition. Moreover, we study the weight gain due to calcium sulfate dihydrate (gypsum) scale accumulation on these materials and show 55% and 77% reduction on REOs in comparison with bare glass and stainless-steel, respectively. We also evaluate the adhesion forces between salt and test materials using atomic force microscopy with a gypsum microparticle adhered onto a tipless cantilever. We show adhesion force between salt particles and REO surfaces is about half that of bare glass and stainless-steel because of the lower surface energy and polar component. We expect REO ceramics would find widespread applicability as robust scale-phobic surfaces in various industries.

Scale Deposition Inhibiting Composites by HDPE/Silicified Acrylate Polymer/Nano-Silica for Landfill Leachate Piping

Scaling commonly occurs at pipe wall during landfill leachate collection and transportation, which may give rise to pipe rupture, thus posing harm to public health and environment. To prevent scaling, this study prepared a low surface energy nanocomposite by incorporating silicone-acrylate polymer and hydrophobically modified nano-SiO₂ into the high-density polyethylene (HDPE) substrate. Through the characterization of contact angle, scanning electron microscopy and thermogravimetry, the results showed that the prepared composite has low wettability and surface free energy, excellent thermal stability and acid-base resistance. In addition, the prepared composite was compared with the commercial HDPE pipe material regarding their performance on anti-scaling by using an immersion test that places their samples into a simulated landfill leachate. It was apparent that the prepared composite shows better scaling resistance. The study further expects to provide insight into pipe materials design and manufacture, thus to improve landfill leachate collection and transportation.

On Coating Techniques for Surface Protection: A Review

A wide variety of coating methods and materials are available for different coating applications with a common purpose of protecting a part or structure exposed to mechanical or chemical damage. A benefit of this protective function is to decrease manufacturing cost since fabrication of new parts is not needed. Available coating materials include hard and stiff metallic alloys, ceramics, bio-glasses, polymers, and engineered plastic materials, giving designers a variety freedom of choices for durable protection. To date, numerous processes such as physical/chemical vapor deposition, micro-arc oxidation, sol–gel, thermal spraying, and electrodeposition processes have been introduced and investigated. Although each of these processes provides advantages, there are always drawbacks limiting their application. However, there are many solutions to overcome deficiencies of coating techniques by using the benefits of each process in a multi-method coating. In this article, these coating methods are categorized, and compared. By developing more advanced coating techniques and materials it is possible to enhance the qualities of protection in the future.