High-speed X-ray imaging of the Leidenfrost collapse

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

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

Minimum Leidenfrost Temperature on Smooth Surfaces

During the Leidenfrost effect, a thin insulating vapor layer separates an evaporating liquid from a hot solid. Here we demonstrate that Leidenfrost vapor layers can be sustained at much lower temperatures than those required for formation. Using a high-speed electrical technique to measure the thickness of water vapor layers over smooth, metallic surfaces, we find that the explosive failure point is nearly independent of material and fluid properties, suggesting a purely hydrodynamic mechanism determines this threshold. For water vapor layers of several millimeters in size, the minimum temperature for stability is ≈140 °C, corresponding to an average vapor layer thickness of 10-20  μm.

The thermo-wetting instability driving Leidenfrost film collapse

Above a critical temperature known as the Leidenfrost point (LFP), a heated surface can suspend a liquid droplet above a film of its own vapor. The insulating vapor film can be highly detrimental in metallurgical quenching and thermal control of electronic devices, but may also be harnessed to reduce drag and generate power. Manipulation of the LFP has occurred mostly through experiment, giving rise to a variety of semiempirical models that account for the Rayleigh-Taylor instability, nucleation rates, and superheat limits. However, formulating a truly comprehensive model has been difficult given that the LFP varies dramatically for different fluids and is affected by system pressure, surface roughness, and liquid wettability. Here, we investigate the vapor film instability for small length scales that ultimately sets the collapse condition at the Leidenfrost point. From a linear stability analysis, it is shown that the main film-stabilizing mechanisms are the liquid-vapor surface tension-driven transport of vapor mass and the evaporation at the liquid-vapor interface. Meanwhile, van der Waals interaction between the bulk liquid and the solid substrate across the vapor phase drives film collapse. This physical insight into vapor film dynamics allows us to derive an ab initio, mathematical expression for the Leidenfrost point of a fluid. The expression captures the experimental data on the LFP for different fluids under various surface wettabilities and ambient pressures. For fluids that wet the surface (small intrinsic contact angle), the expression can be simplified to a single, dimensionless number that encapsulates the wetting instability governing the LFP.