Exploiting intermediate wetting on superhydrophobic surfaces for efficient icing prevention

HYPOTHESIS

Superhydrophobic surfaces can effectively prevent the freezing of supercooled droplets in technological systems. Droplets on superhydrophobic surfaces commonly not only wet the top asperities (Cassie State), but also partially penetrate into microstructure due to surface properties, environment, and droplet impact occurring in real-world applications. Implications on ice nucleation can be expected and are little explored. It remains elusive how anti-icing surfaces can be designed to exploit intermediate wetting phenomena.

EXPERIMENTS

We utilized engineered micro-/nanostructures, specifically micropillars, to modulate the wetting fraction in the microstructure. The behavior of intermediate wetting with supercooling and resulting implications on ice nucleation delay when potential nucleation sites are formed in the microcavities were investigated using experimental, theoretical, and simulation components.

FINDINGS

The temperature-dependent wetting fraction in the microstructure increased at supercooled temperatures, partly activated by condensation in the microcavities. At -10/-20 °C, a critical wetting fraction led to maximum ice nucleation delays, with experimental results consistent with theoretical predictions. This critical wetting fraction minimized the effective contact area solid-to-liquid along the partially wetted microstructure. The study establishes physical relations between ice nucleation delays, geometrical surface parameters and wettability properties in the intermediate wetting regime, providing guidance for the design of ice resistant microstructured surfaces.

Nanofluid Droplet Impact on Rigid and Elastic Superhydrophobic Surfaces

Ice accumulation on cold surfaces is a common and serious phenomenon that exists in numerous industrial fields, such as power transmission, wind turbines, and aircraft. Despite recent efforts in mitigating ice accumulation on the cold surface, it remains a challenge to achieve robust anti-icing on the cold surface in terms of nanofluid droplet. Here, we report a rigid superhydrophobic Cu surface and an elastic polydimethylsiloxane (PDMS) superhydrophobic surface to enhance water-repellency performance, characterized by a significant reduction in contact time and a decrease in the spreading ratio. As for the rigid superhydrophobic Cu surface, the underlying mechanism is ascribed to the existence of stable air cushions between the micropillar array, which reduce the contact area and further suppress the heat conduction. As for the elastic PDMS superhydrophobic surface, the rapid detachment of the nanofluid droplet relies on superior surface elasticity, which can further suppress the nanofluid droplet splashing at a high impacting velocity. We believe that this work can provide a new view for the improvement of water-repellency for a wide range of applications.

Icephobicity of Hierarchically Rough Aluminum Surfaces Sequentially Coated with Fluoroalkyl and PDMS Alkoxysilanes

Superhydrophobic surfaces fabricated by grafting 1H,1H,2H,2H-heptadecafluorodecyl trimethoxysilane (FD-TMS) and polydimethylsiloxane triethoxysilane (PDMS-TES) onto a nano-micro hierarchical aluminum (Al) surface are considered to possess substantial anti-icing functionality, with delayed freezing and low ice-adhesion strength (IAS). Verifying the impacts of PDMS and the synergism of PDMS and FD on the anti-icing performance is the goal of this study. Roughness, one of the prerequisites for superhydrophobicity, was obtained by etching Al substrates in aqueous HCl, followed by immersion in boiling water. FD-TMS and PDMS-TES were then coated on the rough Al substrates layer by layer; a congener coated with a single layer was also prepared for comparison. The FD-PDMS_1.92 (1.92 wt.%) coating, in which FD-TMS and PDMS-TES were used as primary and secondary coating materials, respectively, exhibited superior icephobicity, with the lowest IAS of 28 kPa under extremely condensing weather conditions (-20 °C and 70% relative humidity, RH) and the longest freezing delay time of 230 min (at -18 °C). These features are attributed to the incorporation of a dense coating layer with a low-surface-tension FD and the high mobility of PDMS, which lowered the contact area and interaction between the ice and substrate. The substrate coated with FD-PDMS_1.92 exhibited improved durability with an IAS of 63 kPa after 40 icing/melting cycles, which is far less than that achieved with the FD single-layer coating.

Preparation of SiO2 resin coating with superhydrophobic wettability and anti-icing behavior analysis

Among different types of anti-icing coatings, superhydrophobic surfaces have attracted extensive attention due to their excellent water repellency and low thermal conductivity. We report facile spraying time tuning to optimize the superhydrophobic (SHP) surface coating fabrication by a one-step spraying method of mixing SiO2 nanoparticles with epoxy resin (EP), polyamide resin (PAI), and HFTMS. The wettability performance was optimized by adjusting spraying time from 0 s to 25 s to control surface morphology by adjusting surface morphology and line roughness. With spraying time of 20 s, SiO2 molecular clusters on the superhydrophobic surface showed a maximum water contact angle (WCA) of 160.4° ± 1.3° and a sliding angle (SA) of 4.1° ± 1.0°. What's more, the effect of the coatings' icing behavior were studied by icing heat conduction; SHP-20 delayed the icing time for 410 s at -15 °C, and the icing performance of SHP-20 also declined with the decrease of temperature to -9 °C, -12 °C, -15 °C, and -18 °C. The WCA of SHP-20 can remain above 140.9° ± 1.8° after 40 abrasive 1000# sandpaper wear cycles. The results also provide a basis for the preparation of SHP and anti-icing characteristics.

Controlled Continuous Patterning of Spherical Stainless Steel by Multi-Axis Linkage Laser Milling

While laser surface texturing is promising for the fabrication of planar surface microstructures, the continuously patterning with micrometer accuracy of non-planar surface on miniature parts with large curvature by laser ablation is challenging. In the present work, we demonstrate the feasibility of applying the proposed multi-axis laser milling in continuous patterning of 25 mm diameter spherical stainless steel with high uniformity and precision, based on a strategy of simultaneously adjusting the position and the posture of laser-surface interaction point for enabling the constant coincidence of laser beam with ablated surface normal. Specifically, a miniaturized five-axis platform for controlling workpiece motion with high degree-of-freedom is designed and integrated with a fixed nanosecond pulsed laser beam operating at 1064 nm. The precise path of laser-surface interaction point is derived based on the projection and transformation of pre-determined planar pattern on spherical surface. Meanwhile, a virtual prototype of the multi-axis laser milling with embedded interpolation algorithm is established, which enables the generation of NC codes for subsequent laser milling experiments. Furthermore, the sampling of laser processing parameters particularly for spherical surface is carried out. Finally, complex patterns are continuously structured on the spherical surface by employing the proposed multi-axis laser milling method, and subsequent characterization demonstrates both long range uniformity and local high accuracy of the fabricated patterns. Current work provides a feasible method for the continuous laser surface texturing of non-planar surfaces for miniature parts with large curvature.

Laser-Induced Slippery Liquid-Infused Surfaces with Anticorrosion and Wear Resistance Properties on Aluminum Alloy Substrates

Slippery liquid-infused surfaces (SLISs) are developed as a potential alternative to superhydrophobic surfaces (SHSs) to resolve the issues of poor durability in corrosion protection and wear resistance. In this work, we used a simple laser processing technology to prepare a SLIS on the aluminum alloy (7075) surface. The superhydrophobicities of the modified surface and the oil film formed by liquid injection make the corrosive medium difficult to directly contact the surface and thus have a significant effect on corrosion resistance. The water and oil repellent SLIS exhibits durable corrosion resistance and excellent tribological properties compared with the SHS. The anticorrosion and wear resistance performances provided by the composite film have been assessed by multiple methods including the electrochemical test, immersion test, and friction wear test. The results indicate that compared to the bare surface, laser-ablated surface (LAS), and fluoroalkyl silane-modified SHS, the SLIS composite coating has better corrosion resistance and wear resistance, which is of great significance to expand the potential applications of 7075 aluminum alloys. The work provides a research basis for expanding the practical application of SLISs in complex environments.

Design of Icephobic Surfaces by Lowering Ice Adhesion Strength: A Mini Review

Ice accretion can lead to severe consequences in daily life and sometimes catastrophic events. To mitigate the hazard of icing, passive icephobic surfaces have drawn widespread attentions because of their abilities in repelling incoming water droplets, suppressing ice nucleation and/or lowering ice adhesion strength. As time elapses and temperature lowers sufficiently, ice accretion becomes inevitable, and a realistic roadmap to surface icephobicity for various outdoor anti-icing applications is to live with ice but with the lowest ice adhesion strength. In this review, surfaces with icephobicity are critically categorized into smooth surfaces, textured surfaces, slippery surfaces and sub-surface textured surfaces, and discussed in terms of theoretical limit, current status and perspectives. Particular attention is paid to multiple passive anti-icing strategies combined approaches as proposed on the basis of icephobic surfaces. Correlating the current strategies with one another will promote understanding of the key parameters in lowering ice adhesion strength. Finally, we provide remarks on the rational design of state-of-the-art icephobic surfaces with low ice adhesion strength.

Mechanisms of ice formation and propagation on superhydrophobic surfaces: A review

Icephobic surfaces, used as passive anti-icing materials, are in high demand due to the costs, damage, and loss of equipment and lives related to ice formation on outdoor surfaces. The proper design of icephobic surfaces is intertwined with the need for a profound understanding of ice formation processes and how ice propagates over a surface. Ice formation (ice nucleation) and interdroplet freezing propagation are processes that determine the onset of freezing and complete ice coverage on a surface, respectively. Evaluating the nature of these phenomena, along with their interactions with substrate and environmental factors, can offer a step toward designing surfaces having an improved icephobic performance. This review paper is organized to discuss ice nucleation and rate, preferable locations of nucleation, and favorable pathways of freezing (desublimation and condensation-freezing) on superhydrophobic surfaces. Furthermore, as the propagation of ice over a substrate plays a more deterministic role for the complete freezing coverage of a surface than that of ice formation, this review also elucidates possible mechanisms of ice propagation, theoretical backgrounds, and strategies to control this propagation using surface characteristics.

Thermodynamic method for establishment of relationship between icephobicity/superhydrophobicity and microstructure-Based on computing for adhesion work

Superhydrophobic surfaces (SHS) have potential in solving the icing of aircraft, high-voltage overhead transmission lines, and other power network devices exposed to the air. For this reason, we wish to establish the relationship between microstructure and the adhesion work by thermodynamic method, also for analysis of the relationship between the hydrophobicity and icephobicity (or anti-icing). Therefore, respectively considering Cassie-Baxter and Wenzel states, such relationship was theoretically established based on one/two-step surface model, enlightened by natural and artificial SHS. Among it, how to obtain the adhesion work of icing per unit ice-solid interface is the key to this study. Followed by it, hydrothermal experiment, chemical deposition, and etching methods were performed to verify our theoretical results.

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How to model for the SHS based on the natural and artificial SHS;

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Computation for adhesion work (w_aw) per unit area of a water droplet–SHS interface;

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Computation for adhesion work (w_ai) per unit area of a frozen water droplet–SHS interface;

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Computation for reduced adhesion work (w_a2) after icing;

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Hydrothermal experiment, chemical deposition and etching methods were used for validation of modeling.

Icephobic Behavior of UV-Cured Polymer Networks Incorporated into Slippery Lubricant-Infused Porous Surfaces: Improving SLIPS Durability

Ice accretion causes damage on power generation infrastructure, leading to mechanical failure. Icephobic materials are being researched so that ice buildup on these surfaces will be shed before the weight of the ice causes catastrophic damage. Lubricated materials have imposed the lowest-recorded forces of ice adhesion, and therefore lubricated materials are considered the state-of-the-art in this area. Slippery lubricant-infused porous surfaces (SLIPS) are one type of such materials. SLIPS are initially very effective at repelling ice, but the trapped fluid layer that affords their icephobic properties is easily depleted by repeated icing/deicing cycles, even after one deicing event. UV-cured siloxane resins were infused into SLIPS to observe effects on icephobicity and durability. These UV-cured polymer networks enhanced both the icephobicity and longevity of the SLIPS; values of ice adhesion below 10 kPa were recorded, and appreciable icephobicity was maintained up to 10 icing/deicing cycles.

Fabrication and properties of a superhydrophobic film on an electroless plated magnesium alloy

A superhydrophobic film with high stability, self-cleaning function and robust corrosion inhibition on a magnesium alloy.