Spontaneous dewetting transitions of droplets during icing & melting cycle

One-step synthesis of functional slippery lubricated coating with substrate independence, anti-fouling property, fog collection, corrosion resistance, and icephobicity

Ranging from industrial facilities to residential infrastructure, functional surfaces encompassing functionalities such as anti-fouling, fog collection, anti-corrosion, and anti-icing play a critical role in the daily lives of humans, but creating these surfaces is elusive. Bionic dewetting and liquid-infused surfaces have inspired the exploitation of functional surfaces. However, practical applications of these existing surfaces remain challenging because of their inherent shortcomings. In this study, we propose a novel functional slippery lubricated coating (FSLC) based on a simple blend of polysilazane (PSZ), silicone oil, and nano silica. This simple, nonfluorine based, and low-cost protocol promotes not only hierarchical micro-nano structure but also favorable surface chemistry, which facilitates robust silicone oil adhesion and excellent slippery properties (sliding angle: ∼1.6°) on various solid materials without extra processing or redundant treatments. The highly integrated competence of FSLC, characterized by robustness, durability, strong adhesion to substrates, and the ability for large-area preparation, render them ideal for practical production and application. The proposed FSLC holds outstanding application potentials for anti-fouling, self-cleaning, fog collection, anti-corrosion, and anti-icing functionalities.

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.

Comprehensive Evaluation of Anti-icing Performance and Operational Efficiency of Superhydrophobic Propellers

The icing of propellers is a critical factor that affects the safe operation of aircraft. A superhydrophobic surface, with its extremely low wettability, is highly valuable in the field of anti-icing. This study investigates the distribution pattern of ice on propeller surfaces by employing spray coating to create superhydrophobic surfaces. Additionally, it conducts a comparative analysis of thrust and power under icing and non-icing conditions to comprehensively assess the impact of superhydrophobic surfaces on propeller operation efficiency. The results show that superhydrophobic surfaces not only diminish the ice formation area on propeller surfaces but also enhance the traction of propellers under icing conditions, reducing the power consumption of the propeller. The generated thrust can reach up to 1.6 times that of non-superhydrophobic propellers while consuming only one-third of the power. Furthermore, under non-icing conditions, superhydrophobic surfaces exhibit minimal impact on propeller performance.

Dual-Energy-Barrier Stable Superhydrophobic Structures for Long Icing Delay

Using superhydrophobic surfaces (SHSs) with the water-repellent Cassie-Baxter (CB) state is widely acknowledged as an effective approach for anti-icing performances. Nonetheless, the CB state is susceptible to diverse physical phenomena (e.g., vapor condensation, gas contraction, etc.) at low temperatures, resulting in the transition to the sticky Wenzel state and the loss of anti-icing capabilities. SHSs with various micronanostructures have been empirically examined for enhancing the CB stability; however, the energy barrier transits from the metastable CB state to the stable Wenzel state and thus the CB stability enhancement is currently not enough to guarantee a well and appliable anti-icing performance at low temperatures. Here, we proposed a dual-energy-barrier design strategy on superhydrophobic micronanostructures. Rather than the typical single energy barrier of the conventional CB-to-Wenzel transition, we introduced two CB states (i.e., CB I and CB II), where the state transition needed to go through CB I and CB II then to Wenzel state, thus significantly improving the entire CB stability. We applied ultrafast laser to fabricate this dual-energy-barrier micronanostructures, established a theoretical framework, and performed a series of experiments. The anti-icing performances were exhibited with long delay icing times (over 27,000 s) and low ice-adhesion strengths (0.9 kPa). The kinetic mechanism underpinning the enhanced CB anti-icing stability was elucidated and attributed to the preferential liquid pinning in the shallow closed structures, enabling the higher CB-Wenzel transition energy barrier to sustain the CB state. Comprehensive durability tests further corroborated the potentials of the designed dual-energy-barrier structures for anti-icing applications.

Hierarchical Structure with Microcrater Covered with Nanograss Enhancing Condensation and Its Antifrosting/Anti-Icing Performance Inspired by Euphorbia helioscopia L

Over an extended period of evolution and natural selection, a multitude of species developed a diverse array of biological interface features with specific functions. These biological structures provide a rich source of inspiration for the design of bionic structures on superhydrophobic surfaces. Understanding the functional mechanism of plant leaves is of paramount importance for the advancement of new engineering materials and the further promotion of engineering applications of bionic research. The hierarchical structure of microcrater-covered nanograss (MCNG) on the surface of E. helioscopia L. leaf provided the inspiration for the bionic MCNG surface, which was successfully prepared on a copper substrate by hybrid laser micromachining technology and chemical etching. The combined action of texture structure and surface chemistry resulted in a contact angle of 169° ± 1° for MCNG surface droplets and a rolling angle of less than 1°. Notably, the condensation-induced adhesion force does not augment with the increase of the temperature difference, which facilitated the shedding of hot droplets from the surface. The microscope observation revealed a high density of condensed droplets on the MCNG surface and the tangible jumping behavior of the droplets. The fabricated MCNG also demonstrated excellent antifrost/anti-icing abilities in low-temperature and high-humidity environments. Finally, the study confirmed the exceptional mechanical durability and reusability of the MCNG surface through various tests, including scratch damage, sandpaper wear, water flow impact and flushing, and condensation-drying cycle tests. The nanograss can be effectively protected within the microcrater structure. This research presents a promising approach for preventing and/or removing unwanted droplets in numerous engineering applications.

Superdurable Full-Life Superhydrophobic Composite Block

Superhydrophobic materials are attractive for industrial development but plagued by poor mechanical stability. Herein, a superdurable full-life superhydrophobic composite block is designed and fabricated by embedding near-zero contractive superhydrophobic silica aerogel into a rigid iron-nickel foam structured similarly to a regular dodecahedron. The synergistic protection afforded by these materials ensures superrobust mechanical stability for the composite block, which features a high compressive strength of up to ≈7.4 MPa, and ultralow Taber abrasion of down to ≈0.567 mm after withstanding 50 000 cycles, and highly efficient water harvesting capability of up to ≈3114.3 mg min-1 cm-2 at a supercooling degree of 40 K. This robust material system provides a novel strategy to design superhydrophobic materials capable of withstanding extreme conditions, including high temperature, humidity, pressure, and abrasion.

Superhydrophobic Co-MOF-based sponge for efficient oil-water separation utilizing photothermal effect

Effectively addressing crude oil spills remains a global challenge due to its high viscosity and limited flow characteristics. In this study, we successfully prepared a modified sponge (PCP@MS) by embedding the photothermal material of Co-HHTP and coating the melamine sponge (MS) with low-surface-energy polydimethylsiloxane (PDMS). The PCP@MS exhibited outstanding hydrophobicity with WCA of 160.2° and high oil absorption capacity of 59-107 g/g. The PCP@MS showed high separation efficiency of 99.2% for various oil-water mixtures, along with notable self-cleaning properties and mechanical stability. The internal micro-nano hierarchical structure on the sponge surface significantly enhanced light absorption, synergizing with the photo-thermal conversion properties of Co-HHTP, enabled PCP@MS to achieve a surface temperature of 109.2 °C under 1.0 solar light within 300 s. With the aid of solar radiation, PCP@MS is able to heat up quickly and successfully lowering the viscosity of the surrounding crude oil, resulting in an oil recovery rate of 8.76 g/min. Density functional theory (DFT) calculation results revealed that Co-HHTP featured a zero-gap band structure, rendering advantageous electronic properties for full-wavelength light absorption. This in situ solar-heated absorbent design is poised to advance the practical application of viscous oil spill cleanup and recovery.

Facile Preparation of Impalement Resistant, Mechanically Robust and Weather Resistant Photothermal Superhydrophobic Coatings for Anti-/De-icing

Photothermal superhydrophobic coatings hold great promise in addressing the limitations of conventional superhydrophobic anti-icing coatings. However, developing such coatings with excellent impalement resistance, mechanical robustness and weather resistance remains a significant challenge. Here, we report facile preparation of robust photothermal superhydrophobic coatings with all the above advantages. The coatings were prepared by spraying a dispersion consisting of fluorinated silica nanoparticles, a silicone-modified polyester adhesive and photothermal carbon black nanoparticles onto Al alloy plates followed by thermal curing. Thermal curing caused migration of perfluorodecyl polysiloxane from within the coatings to the surface, effectively maintaining a low surface energy despite the presence of the adhesive. Therefore, combined with the hierarchical micro-/nanostructure, dense yet rough nanostructure, adhesion of the adhesive and chemically inert components, the coatings exhibited remarkable superhydrophobicity, impalement resistance, mechanical robustness and weather resistance. Furthermore, the coatings demonstrated excellent photothermal effect even in the -10 °C, 80 % relative humidity and weak sunlight (0.2 sun) environment. Consequently, the coatings showed excellent passive anti-icing and active de-icing performance. Moreover, the coatings have good generalizability and scalability. We are confident that this study will accelerate the practical implementation of photothermal superhydrophobic coatings.

De-icing performance evolution with increasing hydrophobicity by regulating surface topography

It is of great significance to grasp the role of surface topography in de-icing, which however remains unclear yet. Herein, four textured surfaces are developed by regulating surface topography while keeping surface chemistry and material constituents same. Specifically, nano-textures are maintained and micro-textures are gradually enlarged. The resultant ice adhesion strength is proportional to a topography parameter, i.e. areal fraction of the micro-textures, owing to the localized bonding strengthening, which is verified by ice detachment simulation using finite element method. Moreover, the decisive topography parameter is demonstrated to be determined by the interfacial strength distribution between ice and test surface. Such parameters vary from paper to paper due to different interfacial strength distributions corresponding to respective situations. Furthermore, since hydrophobic and de-icing performance may rely on different topography parameters, there is no certain relationship between hydrophobicity and de-icing.

Multi-Scale Superhydrophobic Surface with Excellent Stability and Solar-Thermal Performance for Highly Efficient Anti-Icing and Deicing

Ice accretion can significantly impact the efficiency and safety of outdoor equipment. Solar-thermal superhydrophobic surface is an effective strategy for anti-icing and deicing. However, droplets easily turn to the Wenzel state during the icing and melting cycle processes, significantly increasing the adhesion and making the droplets difficult to remove from the surface. In this work, a triple-scale solar-thermal superhydrophobic surface is prepared on stainless steel 304 by etching, in situ oxidation, and spin-coating TiN nanoparticles for highly efficient deicing and anti-icing. The multi-scale structure enabled the droplets to recover the Cassie state completely after melting. The contact angle decreased from 162.5° to 136.7° during the icing process and gradually increased to 162.1° during the melting process. In addition, metal oxides and TiN nanoparticles enabled the superhydrophobic surface to exhibit a high solar absorptivity (α ¯ solar ${{\bar{\alpha }}_{{\mathrm{solar}}}}$ = 0.925). The synergistic effect of the superhydrophobicity and the solar-thermal performance endowed the designed multi-scale surface with excellent anti-icing and deicing performance. This work contributed to the practical development of anti-icing and deicing applications based on solar-thermal superhydrophobic surfaces.

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.

A simple fabrication of liquid-like polydimethylsiloxane coating for resisting ice adhesion

The rapid realization of efficient anti-icing coatings on diverse substrates is of vital value for practical applications. However, current approaches for rapid preparations of anti-icing coatings are still deficient regarding their surface universality and accessibility. Here, we report a simple processing approach to rapidly form icephobic liquid-like polydimethylsiloxane (PDMS) brushes on various substrates, including metals, ceramics, glass, and plastics. A poly(dimethylsiloxane), trimethoxysilane is applied as a reactant under the catalysis of a minimal amount of acid formed by hydrolysis of dichlorodimethylsilane. With such an advantage, this approach is approved to be applicable of coating metal surfaces with less corrosion. The distinctive flexibility of the PDMS chains provides a liquid-like property to the coating showing low contact angle hysteresis and ice adhesion strength. Notably, the ice adhesion strength remains similar across a wide temperature window, from -70 to -10 °C, with a value of 18.4 kPa. The PDMS brushes demonstrate perfect capability for resisting acid and alkali corrosions, ultra-violet degradation, and even tens of icing/deicing cycles. Moreover, the liquid-like coating can also form at supercooling conditions, such as -20 °C, and shows an outstanding anti-icing/deicing performance, which meets the in situ coating reformation requirement under extreme conditions when it is damaged. This instantly forming anti-icing material will benefit from resisting instantaneous ice accretion on surfaces under extremely cold conditions.

Unraveling the role of vaporization momentum in self-jumping dynamics of freezing supercooled droplets at reduced pressures

Supercooling of water complicates phase change dynamics, the understanding of which remains limited yet vital to energy-related and aerospace processes. Here, we investigate the freezing and jumping dynamics of supercooled water droplets on superhydrophobic surfaces, induced by a remarkable vaporization momentum, in a low-pressure environment. The vaporization momentum arises from the vaporization at droplet's free surface, progressed and intensified by recalescence, subsequently inducing droplet compression and finally self-jumping. By incorporating liquid-gas-solid phase changes involving vaporization, freezing recalescence, and liquid-solid interactions, we resolve the vaporization momentum and droplet dynamics, revealing a size-scaled jumping velocity and a nucleation-governed jumping direction. A droplet-size-defined regime map is established, distinguishing the vaporization-momentum-dominated self-jumping from evaporative drying and overpressure-initiated levitation, all induced by depressurization and vaporization. Our findings illuminate the role of supercooling and low-pressure mediated phase change in shaping fluid transport dynamics, with implications for passive anti-icing, advanced cooling, and climate physics.

Preparation methods and research progress of super-hydrophobic anti-icing surface

The problem of surface icing poses a serious threat to people's economy and safety, especially in the fields of aerospace, wind power generation and circuit transmission. Super-hydrophobic has excellent anti-icing performance, so it has been widely studied. As the most promising anti-icing technology, superhydrophobic anti-icing surface should not only be simple to prepare, but also have excellent comprehensive performance, which can meet the anti-icing task under harsh working conditions and long-term durability. This paper summarizes the basic performance requirements of superhydrophobic surface for anti-icing operation, and then summarizes the preparation methods and existing problems of superhydrophobic surface in recent years. Finally, the future development trend of superhydrophobic anti-icing surface is prospected and discussed, hoping to provide certain technical guidance for the subsequent research of high-performance superhydrophobic anti-icing surface.

Waste for Waste: Interface-Intensified Durable Superhydrophilic-Superoleophobic Collagen Fiber Membrane for Efficient Separation of Cationic Surfactant-Stabilized Oil-in-Water Emulsions

Cationic surfactant-stabilized oil-in-water emulsions pose a significant challenge in separation due to the presence of surfactants. Herein, we develop a collagen-fiber-based CFM-PMDA-TiO2 membrane with unique infiltration properties capable of efficiently separating cationic surfactant-stabilized oil-in-water emulsions by exploiting the charge-demulsification effect. The membrane exhibits superhydrophilic and submerged superoleophobic properties, making it highly suitable for separating a wide range of commercially available cationic surfactant-stabilized oil-in-water microemulsions and nanoemulsions, which demonstrates an exceptional separation efficiency as high as 99.86% and an impressive flux of up to 1436.40 L m-2 h-1. Furthermore, even after a strong subjecting of the membrane to sandpaper abrasion and a full 15 time use, the separation efficacy of oil-in-water emulsions is retained, highlighting the durability, reusability, and economic viability. We propose that these features are enabled by the electrostatic interactions triggered from pyromellitic dianhydride (PMDA) and superhydrophilic-superoleophobic membrane intensified by the TiO2 on the unique collagen fiber membrane. Outcomes emphasize the versatility and potential of our membrane in addressing emulsified oily wastewater hurdles.

Highly Efficient Photothermal Icephobic/de-Icing MOF-Based Micro and Nanostructured Surface

Photothermal materials have gained considerable attention in the field of anti-/de-icing due to its environmental friendliness and energy saving. However, it is always significantly challenging to obtain solar thermal materials with hierarchical structure and simultaneously demonstrate both the ultra-long icing delay ability and the superior photothermal de-icing ability. Here, a photothermal icephobic MOF-based micro and nanostructure surface (MOF-MNS) is presented, which consists of micron groove structure and fluorinated MOF nanowhiskers. The optimal MOF-M250 NS can achieve solar absorption of over 98% and produce a high temperature increment of 65.5 °C under 1-sun illumination. Such superior photothermal-conversion mechanism of MOF-M250 NS is elucidated in depth. In addition, the MOF-M250 NS generates an ultra-long icing delay time of ≈3960 s at -18 °C without solar illumination, achieving the longest delay time, which isn't reported before. Due to its excellent solar-to-heat conversation ability, accumulated ice and frost on MOF-M250 NS can be rapidly melted within 720 s under 1-sun illumination and it also holds a high de-icing rate of 5.8 kg m-2 h-1 . MOF-M250 NS possesses the versatility of mechanical robustness, chemical stability, and low temperature self-cleaning, which can synergistically reinforce the usage of icephobic surfaces in harsh conditions.

Advancing Inorganic Microcapsule Fabrication through Frozen-Assisted Interfacial Reactions Utilizing Liquid Marbles

Inorganic microcapsules (IMs) have gained significant attention as versatile platforms for delivering functional agents in various fields. Traditional template-dependent methods employing hard templates often involve complex and harsh template removal processes. Achieving IMs with diverse composition and structure remains challenging with current preparation strategies. Therefore, in this work, we have for the first time demonstrated an extremely facile and efficient liquid-marbles-based template approach for fabricating pure inorganic microcapsules via interfacial reaction in a mild aqueous solution. The water-water reaction interface is created by changing the wettability of the liquid marble (LM) surface through the icing-melting process. The composition and function of the inorganic shell could be easily adjusted by varying the inorganic reagent species of the interfacial reaction, the hydrophobic particle of the shell, and the reaction environment according to the specific requirements of the application field. Such an approach provides a flexible platform for material preparation.

Golden section criterion to achieve droplet trampoline effect on metal-based superhydrophobic surface

Clarifying the consecutive droplet rebound mechanisms can provide scientific inspirations to regulate dynamic wettability of superhydrophobic surface, which facilitates the practical applications on efficient heat control and active anti-icing. Generally, droplet rebound behaviors are directly affected by surface structure and Weber number. Here, we report a novel "golden section" design criterion to regulate the droplet rebound number determined by the structure spacing, subverting conventional knowledge. Especially, the droplet can continuously rebound for 17 times on the metal-based surface, exhibiting an amazing phenomenon of "droplet trampoline". The droplet rebound number has been experimentally revealed to be closely related to Weber number. We propose novel quantitative formulas to predict droplet rebound number and clarify the coupling effect of the structure spacing and the Weber number on the rebound mechanisms, which can be utilized to establish the regulation criteria of rebound numbers and develop novel metal-based superhydrophobic materials.

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.

Self-Driven Droplet Motions Below their Icing Points

Liquid fluidity is a most key prerequisite for a broad range of technologies, from energy, fluid machineries, microfluidic devices, water, and oil transportation to bio-deliveries. While from thermodynamics, the liquid fluidity gradually diminishes as temperature decreases until completely solidified below icing points. Here, self-driven droplet motions are discovered and demonstrated occurring in icing environments and accelerating with both moving distances and droplet volumes. The self-driven motions, including self-depinning and continuous wriggling, require no surface pre-preparation or energy input but are triggered by the overpressure spontaneously established during icing and then continuously accelerated by capillary pulling of frosts. Such self-driven motions are generic to a broad class of liquid types, volumes, and numbers on various micro-nanostructured surfaces and can be facilely manipulated by introducing pressure gradients spontaneously or externally. The discovery and control of self-driven motions below icing points can greatly broaden liquid-related applications in icing environments.

Large-scale assembly of isotropic nanofiber aerogels based on columnar-equiaxed crystal transition

Ice-templating technology holds great potential to construct industrial porous materials from nanometers to the macroscopic scale for tailoring thermal, electronic, or acoustic transport. Herein, we describe a general ice-templating technology through freezing the material on a rotating cryogenic drum surface, crushing it, and then re-casting the nanofiber slurry. Through decoupling the ice nucleation and growth processes, we achieved the columnar-equiaxed crystal transition in the freezing procedure. The highly random stacking and integrating of equiaxed ice crystals can organize nanofibers into thousands of repeating microscale units with a tortuous channel topology. Owing to the spatially well-defined isotropic structure, the obtained Al2O3·SiO2 nanofiber aerogels exhibit ultralow thermal conductivity, superelasticity, good damage tolerance, and fatigue resistance. These features, together with their natural stability up to 1200 °C, make them highly robust for thermal insulation under extreme thermomechanical environments. Cascading thermal runaway propagation in a high-capacity lithium-ion battery module consisting of LiNi0.8Co0.1Mn0.1O2 cathode, with ultrahigh thermal shock power of 215 kW, can be completely prevented by a thin nanofiber aerogel layer. These findings not only establish a general production route for nanomaterial assemblies that is conventionally challenging, but also demonstrate a high-energy-density battery module configuration with a high safety standard that is critical for practical applications.

Chemical Etching, Thermally Driven Combination Strategy to Fabricate Superhydrophobic Fe-Based Amorphous Coatings with Excellent Anticorrosion Property: Based on Hydroxylation Effect

Fe-based amorphous coatings are ideal materials for surface protection due to their outstanding mechanical properties and corrosion resistance. However, coating defects are inevitably formed during the preparation of coatings by thermal spray technology, which seriously affects the corrosion performance. Inspired by bionics, conceiving superhydrophobic surfaces with liquid barrier properties has become a new idea for the corrosion protection of metal surfaces. In this work, based on surface hydroxylation, we designed a superhydrophobic Fe-based amorphous coating with corrosion resistance by chemical etching combined with a thermally driven preparation strategy. The obtained superhydrophobic coatings exhibit liquid repellency (contact angle >150°) and excellent corrosion resistance (corrosion current density and passive current density reduced by 3 orders of magnitude). The results revealed that the superhydrophobic behavior stems from the construction of hydroxyl-induced surface micro-/nanomultilevel aggregates (cluster structures). The hydrophobic agent layer deposited on the surface of cluster aggregates and the nanoparticle elements that constitute the clusters dominate the corrosion resistance of the coating. This work provides an effective guide to the design of high-corrosion-resistant Fe-based amorphous alloy coatings and promotes their engineering applications.

Freezing Characteristics of a Water Droplet on a Multiscale Superhydrophobic Surface

Superhydrophobic surfaces have the potential to retard ice formation owing to their super water-repellant nature arising from high static contact angle and low contact angle hysteresis. Most of the previous studies have focused on patterned surfaces with mono-scaled prismatic structures. In contrast, the freezing behavior on multiscaled rough superhydrophobic surfaces that are of practical significance is relatively little studied. This article presents, for the first time, the freezing dynamics of a water droplet interacting with multiscale fractal superhydrophobic surfaces which validates well with experimental measurements. It is shown that the dual effects of increased contact angle and poor interfacial conduction due to trapped air cavities within the roughness features of the superhydrophobic surface lead to increasing freezing time with increasing surface hydrophobicity, determined as a function of the fractal surface parameters. A comparison of the freezing dynamics of sessile droplets of identical contact angle on a smooth versus a rough superhydrophobic surface shows that interfacial asperity thermal resistance contributes to over 14% increase in the freeze time. It is further shown that by tailoring the multiscale characteristics, the freeze time may be increased by up to 7-fold compared to freezing on a smooth surface. The application of the numerical model to studying ice formation on several practical superhydrophobic surfaces of a range of metallic materials and fabrication methods is also discussed, which offers guidelines for the design of anti-icing surfaces in practice.

Interdependence of Surface Roughness on Icephobic Performance: A Review

Ice protection techniques have attracted significant interest, notably in aerospace and wind energy applications. However, the current solutions are mostly costly and inconvenient due to energy-intensive and environmental concerns. One of the appealing strategies is the use of passive icephobicity, in the form of coatings, which is induced by means of several material strategies, such as hydrophobicity, surface texturing, surface elasticity, and the physical infusion of ice-depressing liquids, etc. In this review, surface-roughness-related icephobicity is critically discussed to understand the challenges and the role of roughness, especially on superhydrophobic surfaces. Surface roughness as an intrinsic, independent surface property for anti-icing and de-icing performance is also debated, and their interdependence is explained using the related physical mechanisms and thermodynamics of ice nucleation. Furthermore, the role of surface roughness in the case of elastomeric or low-modulus polymeric coatings, which typically instigate an easy release of ice, is examined. In addition to material-centric approaches, the influence of surface roughness in de-icing evaluation is also explored, and a comparative assessment is conducted to understand the testing sensitivity to various surface characteristics. This review exemplifies that surface roughness plays a crucial role in incorporating and maintaining icephobic performance and is intrinsically interlinked with other surface-induced icephobicity strategies, including superhydrophobicity and elastomeric surfaces. Furthermore, the de-icing evaluation methods also appear to be roughness sensitive in a certain range, indicating a dominant role of mechanically interlocked ice.

Laser Interference Lithography-A Method for the Fabrication of Controlled Periodic Structures

A microstructure determines macro functionality. A controlled periodic structure gives the surface specific functions such as controlled structural color, wettability, anti-icing/frosting, friction reduction, and hardness enhancement. Currently, there are a variety of controllable periodic structures that can be produced. Laser interference lithography (LIL) is a technique that allows for the simple, flexible, and rapid fabrication of high-resolution periodic structures over large areas without the use of masks. Different interference conditions can produce a wide range of light fields. When an LIL system is used to expose the substrate, a variety of periodic textured structures, such as periodic nanoparticles, dot arrays, hole arrays, and stripes, can be produced. The LIL technique can be used not only on flat substrates, but also on curved or partially curved substrates, taking advantage of the large depth of focus. This paper reviews the principles of LIL and discusses how the parameters, such as spatial angle, angle of incidence, wavelength, and polarization state, affect the interference light field. Applications of LIL for functional surface fabrication, such as anti-reflection, controlled structural color, surface-enhanced Raman scattering (SERS), friction reduction, superhydrophobicity, and biocellular modulation, are also presented. Finally, we present some of the challenges and problems in LIL and its applications.

Directional Drop Rebound on Adhesive-Gradient Micro-Nanostructured Surfaces Formed by a Femtosecond Laser

The dynamic behavior of droplets hitting a solid surface has received extensive attention due to its broad application prospects. Additionally, controlling the rebound behavior of impacting droplets is an important research topic. Current methods for investigating this behavior focus on the construction of a differentiated wettability surface, which is characterized by contact angle measurements, or a differentiated topography surface, which is represented by geometric height. This information allows one to obtain the nonuniform kinetic energy distribution of rebounding droplets and to realize control of rebounding droplet behavior. In this paper, femtosecond laser processing is proposed for the fabrication of an anisotropic surface with differences in adhesion, which allows for the control of impacting droplet rebound behavior. The experimental results show that the micro-nanostructure of the surface affects its adhesion. By changing the micro-nanostructure of the solid surface, the difference in surface adhesion can be controlled, thereby realizing precise control of impacting droplet rebound behavior. This study demonstrates that the micro-nanostructured surface formed by a femtosecond laser can be used to control a droplet rebound direction and landing site, which is of great significance to the development of liquid transport, microfluidic devices, and other fields.

Recent Advances in Superhydrophobic Surfaces and Applications on Wood

Superhydrophobic substances were favored in wood protection. Superhydrophobic treatment of wood is of great significance for improving the service life of wood and expanding its application fields, such as improving dimensional stability, durability, UV stability, and reducing wetting. The superhydrophobic phenomenon is attributed to the interaction of micro/nano hierarchical structure and low surface energy substances of the wood surface. This is the common method for obtaining superhydrophobic wood. The article introduces the common preparation methods of superhydrophobic wood material coatings and their mechanisms. These techniques include lithography, sol–gel methods, graft copolymerization, chemical vapor deposition, etc. The latest research progress of superhydrophobic wood material coatings application at domestic and overseas is reviewed, and the current status of superhydrophobic coating application in wood materials and construction is summarized. Finally, superhydrophobic on wood in the field of applied research is presented, and the development trend in the field of functional improvement of wood is foreseen.

Overflow Control for Sustainable Development by Superwetting Surface with Biomimetic Structure

Liquid flowing around a solid edge, i.e., overflow, is a commonly observed flow behavior. Recent research into surface wetting properties and microstructure-controlled overflow behavior has attracted much attention. Achieving controllable macroscale liquid dynamics by manipulating the micro-nanoscale liquid overflow has stimulated diverse scientific interest and fostered widespread use in practical applications. In this review, we outline the evolution of overflow and present a critical survey of the mechanism of surface wetting properties and microstructure-controlled liquid overflow in multilength scales ranging from centimeter to micro and even nanoscale. We summarize the latest progress in utilizing the mechanisms to manipulate liquid overflow and achieve macroscale liquid dynamics and in emerging applications to manipulate overflow for sustainable development in various fields, along with challenges and perspectives.

Preparation of a Superhydrophobic Surface by a One-Step Powder Pressing Method with Liquid Silicone Rubber As the Carrier

The preparation methods of the superhydrophobic surface play an important role in its application, but most of the existing preparation methods are complicated in operation, high in cost, and polluting to the environment. In order to find a simple, rapid, low-cost, and nonenvironmentally polluting preparation method of the superhydrophobic surface, this paper used liquid silicone rubber as the carrier. Before the liquid silicone rubber was nearly cured, it was evenly covered with a layer of silicon dioxide powder, and then 5 N weight was used to compact the powder on the rubber surface, so that the superhydrophobic surface was quickly formed on its surface. The wettability, bouncing performance, self-cleaning performance, and bending durability of liquid silicone rubber before and after treatment were compared. The results show that the static contact angle and rolling angle of the liquid silicone rubber after powder pressing were 158.22 ± 2.01° and 1.00 ± 0.50°, respectively. Moreover, the superhydrophobic surface formed by the powder pressing method had good self-cleaning performance, high temperature resistance, bending resistance, and excellent droplet bounce performance. The strategy of preparing a superhydrophobic surface by a one-step powder pressing method may be applied to the preparation of the superhydrophobic surface on a large scale.

Estimation of surface free energy at microstructured surface to investigate intermediate wetting state for partial wetting model

While partial wetting at nano-/microstructured surfaces can be described using the intermediate wetting state between the Cassie-Baxter and Wenzel states, the limitations of the partial wetting model remain unclear. In this study, we performed surface free energy analysis at a microstructured Si-water interface from both theoretical and experimental viewpoints. We experimentally measured the water contact angle on microstructured Si surfaces with square holes and compared the measured values with theoretical predictions. Furthermore, the surface free energy was analyzed using the effective wetting area estimated from the measured contact angle and electrochemical impedance spectroscopy results. We verified the validity of the partial wetting model for fabricated Si surfaces with a hole aperture a less than 230 μm and a hole height h of 12 μm, and for a < 400 μm, h = 40 μm. The model was found to be applicable to microstructured Si surfaces with a/h < 10.

Passive Anti-Icing Performances of the Same Superhydrophobic Surfaces under Static Freezing, Dynamic Supercooled-Droplet Impinging, and Icing Wind Tunnel Tests

Overcoming ice accretion on external aircraft wing surfaces plays a crucial role in aviation, and developing environmentally friendly passive anti-icing surfaces is considered to be a promising strategy. Superhydrophobic surfaces (SHSs) have attracted increasing attention due to their potential advantages of keeping the airframe dry without causing additional aerodynamic losses. However, the passive anti-icing performances of SHSs reported to date varied a lot under different icing test conditions. Therefore, a systematic investigation is necessary to elucidate the icing conditions where SHSs can remain effective and pave the way for SHSs toward practical anti-icing applications. Herein, we designed and fabricated a typical type of SHS featuring dual-scale hierarchical structures with arrayed micromountains (with both spacings and heights of tens of micrometers) covered by single-scale sandy-corrugation-like periodic structures (with both spacings and heights of only several micrometers) (termed SS1). Its anti-icing performances under three representative icing conditions, including static water freezing, dynamic supercooled-droplet impinging, and icing wind tunnel conditions, were comparatively investigated. The SS1 SHS maintained a lower static ice-adhesion strength (<60 kPa even after 50 deicing cycles at temperatures as low as -25 °C), which was attributed to a cumulative cracking effect facilitating the ice detachment. Within the laboratory dynamic icing tests, the SS1 SHSs with micromountain heights of 20-30 μm performed optimally in the antiadhesion of supercooled droplets (at an impinging velocity of 3.4 m/s and temperatures of -5 to -25 °C). In spite of the significant anti-icing performances of the SS1 SHSs in both static and dynamic laboratory tests, they could hardly sustain reliable passive anti-icing performances in harsher icing wind tunnel tests with supercooled droplets impinging their surfaces at velocities of up to 50 m/s at a temperature of -5 °C for 10 min. This study can inspire the development of improved SHSs for achieving satisfactory anti-icing performances in real-aviation conditions.

Numerical Analysis of the Free-Falling Process of a Water Droplet at Different Temperatures

The collision behavior and ice formation of a water droplet are affected by its falling process. In this paper, the two-phase flow of air and a water droplet at a specific temperature is adopted to investigate the processes of falling and freezing of a single water droplet. To track the air–water droplet interface and the temperature distribution, the level-set method and the non-isothermal flow coupling method are used, and the freezing model is added into the water’s control equations. The numerical results indicated that with the initial temperature at 283.15 K and the spherical shape, the water droplet changes to the shape of a straw hat at 293.15 K and a drum at 293.15 K but an oval face in freezing temperatures at 0.10 s. There is an obvious drop in the downward velocity when the water droplet falls in mild temperatures at 0.09 s. The downward velocity of the water droplet in air at sub-zero temperatures has a continuous increase during the time span from 0 s to 0.10 s. There is also an obvious difference when the water droplet impinges on the solid bottom. Lastly, the freezing of sessile water droplets attached on the horizontal surface is helpful to reveal the unique phase change process of water droplets in cold air.

Superhydrophobic microstructures for better anti-icing performances: open-cell or closed-cell?

Based on geometrical characteristics, all surface microstructures are categorized into two types: closed-cell and open-cell structures. Closed-cell structures are well-known to have more stable and durable superhydrophobicity at room temperatures. However, in low-temperature environments where massive environmentally induced physical changes emerge, whether closed-cell surfaces can maintain good anti-icing performances has not yet been confirmed, and thus how to design optimal superhydrophobic anti-icing microstructures is rarely reported. Here, we apply an ultrafast laser to fabricate superhydrophobic surfaces with tunable patterned micro-nanostructures from a complete closed-cell to different ratios and to a complete open-cell. We discover that droplets on closed-cell structures completely degrade to the high-adhesion Wenzel state after icing and melting cycles while those on the open-cell structures well recover to the original Cassie-Baxter state. We propose an improved ideal gas model to clarify the mechanisms that the decreased air pocket pressure and the air dissolution on closed-cell structures induce easy impalement during icing and the difficult recovery during melting, paving the way for optimizing the anti-icing structure design. The optimized open-cell surfaces exhibit over 33 times lower ice adhesion strengths (1.4 kPa) and long-term icephobic durability (<20 kPa after 33 deicing cycles) owing to the increased air pocket pressure at low temperatures. Significant dewetting processes during condensation endow the open-cell structures with more remarkable high-humidity resistance and anti-frosting properties. Our study reveals the general design principle of superhydrophobic anti-icing structures, which might guide the design of superhydrophobic anti-icing surfaces in practical harsh environments.

PDMS/PVDF Electrospinning Membranes for Water-in-Oil Emulsion Separation and UV Protection

With industry development, the separation of oily wastewater is becoming more critical. Inspired by organisms such as lotus leaves, biomimetic superhydrophobic surfaces with micro-nano structures have shown great potential in this regard. In this work, PDMS/PVDF oil-water separation membranes with designed microstructures were prepared by electrospinning technology. The membrane-forming effect of electrospinning with different ratios of PDMS and PVDF was studied. The study found that membranes with high PDMS content were more likely to form microspheres, and PDMS tended to concentrate on the microspheres. The results also showed that the microspheres would bring better hydrophobicity to the membrane. When the ratio of PDMS to PVDF is 1:2, the membrane has a water contact angle of up to 150° and an oil contact angle of 0°. At this ratio, the separation efficiency of the membrane for the water-in-oil emulsion is 98.7%, and it can still maintain more than 98% after ten separation cycles, which is a good candidate for oil-water separation. Furthermore, microspheres enable the membrane to achieve macroscopic uniformity and microscopic phase separation so that the membranes have both good elongation and fracture strength. In addition, the PDMS/PVDF membranes also exhibit excellent UV resistance, and their UV protection factor is greater than 185, making them a potential UV protective material.

Heat Transfer Characteristics of Carbon-Based Photothermal Superhydrophobic Materials with Thermal Insulation Micropores During Anti-icing/Deicing

Photothermal deicing is a noncontact, economically, efficient, and environmentally friendly melting/preventing ice method. Obtaining a cheap, easily fabricated material with high photothermal conversion and deicing efficiency is a challenge. Here, carbon-based photothermal superhydrophobic materials with thermal insulation micropores were prepared by using the salt-template. We demonstrate that the microholes array structure can enhance light absorption and hydrophobicity of the material, and the micropores structure can inhibit the heat transfer from the surface to the subcooled substrate, which synergistically greatly enhances the photothermal conversion. A heat transfer model was established to clarify the influence mechanisms of air cushion on interfacial heat transfer during the photothermal anti-icing and deicing process. The self-cleaning, flexibility, mechanical, and chemical stability tests show that the material has the potential for outdoor application. The prepared materials with high photothermal deicing efficiency provide a new way for the anti-icing and deicing of outdoor equipment.

In Situ Activation of Superhydrophobic Surfaces with Triple Icephobicity at Low Temperatures

Superhydrophobic surfaces have been widely studied due to their potential applications in aerospace fields. However, superhydrophobic surfaces with excellent water-repellent, anti-icing, and icephobic performances at low temperatures have rarely been reported. Herein, superhydrophobic surfaces with heating capability were prepared by etching square micropillar arrays on the surface of multiwalled carbon nanotube (MWCNT)/poly(dimethylsiloxane) (PDMS) films. The fabricated superhydrophobic surface has triple icephobicity, which can be activated even at low temperatures. The triple icephobicity is triggered by an applied voltage to achieve excellent water-repellent and icephobic capabilities, even at -40 °C. Additionally, theoretical calculations reveal that a droplet on a superhydrophobic surface loses heat at a rate of 8.91 × 10^-5 J/s, which is 2 orders of magnitude slower than a flat surface (2.15 × 10^-3 J/s). Also, at -40 °C, the mechanical interlocking force formed between the superhydrophobic surface and ice can be released by the heating property of the superhydrophobic surface. This low-energy, multifunctional superhydrophobic surface opens up new possibilities for bionic smart multifunctional materials in icephobic applications.

Bio-Inspired Hierarchical Micro/Nanostructured Surfaces for Superhydrophobic and Anti-Ice Applications

We report a scalable and cost-effective fabrication approach for constructing bio-inspired micro/nanostructured surfaces. It involves silicon microstructure etching using a deep reactive ion etch (DRIE) method, nanowires deposition via glancing angle deposition (GLAD) process, and fluorocarbon thin film deposition. Compared with the smooth, microstructured, and nanostructured surfaces, the hierarchical micro/nanostructured surfaces obtained via this method showed the highest water contact angle of ∼161° and a low sliding angle of <10°. It also offered long ice delay times of 2313 s and 1658 s at −5°C and −10°C respectively, more than 10 times longer than smooth surfaces indicating excellent anti-icing properties and offering promising applications in low-temperature environments. These analyses further proved that the surface structures have a significant influence on surface wettability and anti-icing behavior. Hence, the GLAD process which is versatile and cost-effective offers the freedom of constructing nanostructures on top of microstructures to achieve the required objective in the fabrication of micro/nanostructured surfaces when compared to other fabrication techniques.