Dropwise condensation on bioinspired hydrophilic-slippery surface

Theoretical and Three-Dimensional Molecular Dynamics Study of Droplet Wettability and Mobility on Lubricant-Infused Porous Surfaces

Profiting from their slippery nature, lubricant-infused porous surfaces endow with droplets excellent mobility and consequently promise remarkable heat transfer improvement for dropwise condensation. To be a four-phase wetting system, the droplet wettability configurations and the corresponding dynamic characteristics on lubricant-infused porous surfaces are closely related to many factors, such as multiple interfacial interactions, surface features, and lubricant thickness, which keeps a long-standing challenge to promulgate the underlying physics. In this work, thermodynamically theoretical analysis and three-dimensional molecular dynamics simulations with the coarse-grained water and hexane models are carried out to explore droplet wettability and mobility on lubricant-infused porous surfaces. Combined with accessible theoretical criteria, phase diagrams of droplet configurations are constructed with a comprehensive consideration of interfacial interactions, surface structures, and lubricant thickness. Subsequently, droplet sliding and coalescence dynamics are quantitatively defined under different configurations. Finally, in terms of the promotion of dropwise condensation, a non-cloaking configuration with the encapsulated state underneath the droplet is recommended to achieve high droplet mobility owing to the low viscous drag of the lubricant and the eliminated pinning effect of the contact line. On the basis of the low oil-water and water-solid interactions, a stable lubricant layer with a relatively low thickness is suggested to construct slippery surfaces.

The temperature dependent dynamics and periodicity of dropwise condensation on surfaces with wetting heterogeneities

HYPOTHESIS

Biphilic surfaces, namely surfaces comprising hydrophilic areas with a (super)hydrophobic background, are used in nature and engineering for controlled dropwise condensation and liquid transport. These, however, are highly dependent on the surface temperature and subcooling.

EXPERIMENTS

Here, biphilic surfaces were cooled inside a rotatable environmental chamber under controlled humidity. The condensation dynamics on the surface was quantified, depending on the subcooling, and compared to uniform superhydrophobic (USH) surfaces. Rates of condensation and transport were analyzed in terms of droplet number and size, covered area and fluid volume over several length scales. Specifically, from microscale condensation to macroscale droplet roll-off.

FINDINGS

Four phases of condensation were identified: a) initial nucleation, b) droplets on single patches, c) droplets covering adjacent patches and d) multi-patch droplets. Only the latter become mobile and roll off the surface. Cooling the surface to temperatures between T = 2-16 °C shows that lowering the temperature shortens some of the condensation parameters linearly, while others follow a power law, as expected from the theory of condensation. The temperature dependent condensation dynamics on (super)biphilic surfaces is faster in comparison to uniform superhydrophobic surfaces. Nevertheless, within time intervals of a few hours, droplets are mostly immobile. This sets guiding lines for using biphilic surfaces in applications such as water collection, heat transfer and separation processes. Generally, biphilic surfaces are suitable for applications in which fluids should be collected, concentrated and immobilized in specific areas.

Dropwise Condensation in Ambient on a Depleted Lubricant-Infused Surface

Durability of a lubricant-infused surface (LIS) is critical for heat transfer, especially in condensation-based applications. Although LIS promotes dropwise condensation, each departing droplet condensate acts as a lubricant-depleting agent due to the formation of wetting ridge and cloaking layer around the condensate, thus gradually leading to drop pinning on the underlying rough topography. Condensation heat transfer further deteriorates in the presence of non-condensable gases (NCGs) requiring special experimental arrangements to eliminate NCGs due to a decrease in the availability of nucleation sites. To address these issues while simultaneously improving heat-transfer performance of LIS in condensation-based systems, we report fabrication of both fresh LIS and a lubricant-depleted LIS using silicon porous nanochannel wicks as an underlying substrate. Strong capillarity in the nanochannels helps retain silicone oil (polydimethylsiloxane) on the surface even after it is severely depleted under tap water. The effect of oil viscosity was investigated for drop mobility and condensation heat transfer under ambient conditions, i.e., in the presence of NCGs. While fresh LIS prepared using 5 cSt silicone oil exhibited a low roll-off angle (∼1°) and excellent water drop (5 μL) sliding velocity ∼66 mm s^-1, it underwent rapid depletion as compared to higher viscosity oils. Condensation performed on depleted nanochannel LIS with higher viscosity oil (50 cSt) resulted in a heat-transfer coefficient (HTC) of ∼2.33 kW m^-2 K^-1, which is a ∼162% improvement over flat Si-LIS (50 cSt). Such LIS promote fast drop shedding as is evident from the little change in the fraction of drops with diameter <500 μm from ∼98% to only ∼93% after 4 h of condensation. Improvement in HTC was also seen in condensation experiments conducted for 3 days where a steady HTC of ∼1.46 kW m^-2 K^-1 was achieved over the last 2 days. The ability of reported LIS to maintain long-term hydrophobicity and dropwise condensation will aid in designing condensation-based systems with improved heat-transfer performance.

Review of droplet dynamics and dropwise condensation enhancement: Theory, experiments and applications

Droplet dynamics and condensation phenomena are widespread in nature and industrial applications, and the fundamentals of various technological applications. Currently, with the rapid development of interfacial materials, microfluidics, micro/nano fabrication technology, as well as the intersection of fluid mechanics, interfacial mechanics, heat and mass transfer, thermodynamics and reaction kinetics and other disciplines, the preparation and design of various novel functional surfaces have contributed to the local modulation of droplets (including nucleation, jumping and directional migration) and the improvement of condensation heat transfer, further deepening the understanding of relevant mechanisms. The wetting and dynamic characteristics of droplets involve complex solid-liquid interfacial interactions, so that the local modulation of microdroplets and the extension of enhanced condensation heat transfer by means of complex micro/nano structures and hydrophilic/hydrophobic properties is one of the current hot topics in heat and mass transfer research. This work presents a detailed review of several scientific issues related to the droplet dynamics and dropwise condensation heat transfer under the influence of multiple factors (including fluid property, surface structure, wettability, temperature external field, etc.). Firstly, the basic theory of droplet wetting on the solid wall is introduced, and the mechanism of solid-liquid interfacial interaction involving droplet jumping and directional migration on the functional surfaces under the various influencing factors is discussed. Optimizing the surface structure for the local modulation of droplets is of guidance for condensation heat transfer. Secondly, we summarize the existing theoretical models of dropwise condensation applicable to various functional surfaces and briefly outline the current numerical models for simulating dropwise condensation at different scales, as well as the fabricating techniques of coatings and functional surfaces for enhancing heat transfer. Finally, the relevant problems and challenges are summarized and future research is discussed.

Bioinspired functional SLIPSs and wettability gradient surfaces and their synergistic cooperation and opportunities for enhanced condensate and fluid transport

Bioinspired smart functional surfaces have received increasing attention in recent years owed to their tunable wettability and enhanced droplet transport suggesting them as excellent candidates for industrial and nanotechnology-related applications. More specifically, bioinspired slippery lubricant infused porous surfaces (SLIPSs) have been proposed for their low adhesion enabling continuous dropwise condensation (DWC) even of low-surface tension fluids. In addition, functional surfaces with chemical and/or structural wettability gradients have also been exploited empowering spontaneous droplet transport in a controlled manner. Current research has focused on the better understanding of the mechanisms and intimate interactions taking place between liquid droplets and functional surfaces or on the forces imposed by differences in surface wettability and/or by Laplace pressure owed to chemical or structural gradients. Nonetheless, less attention has been paid to the synergistic cooperation of efficiently driving droplet transport via chemical and/or structural patterns/gradients on a low surface energy/adhesion background imposed by SLIPSs, with the consequent promising potential for microfluidics and condensation heat transfer applications amongst others. This review provides a detailed and timely overview and summary on recent advances and developments on bioinspired SLIPSs and on wettability gradient surfaces with focus on their synergistic cooperation for condensation and fluid transport related applications. Firstly, the fundamental theory and mechanisms governing complex droplet transport on homogeneous, on wettability gradient surfaces and on inclined SLIPSs are introduced. Secondly, recent advances on the fabrication and characterization of SLIPSs and functional surfaces are presented. Then, the condensation performance on such functional surfaces comprising chemical or structural wettability gradients is reviewed and their applications on condensation heat transfer are summarized. Last a summary outlook highlighting the opportunities and challenges on the synergistic cooperation of SLIPSs and wettability gradient surfaces for heat transfer as well as future perspective in modern applications are presented.

Droplet Nucleation and Growth in the Presence of Noncondensable Gas: A Molecular Dynamics Study

The presence of noncondensable gas (NCG) followed by undesirable heat transfer deterioration cannot be avoided in some situations. In this work, droplet nucleation and growth for the Ar-Ne mixed system are investigated using molecular dynamics simulation. Different droplet state transition modes corresponding to the subcooling degree or NCG content are obtained. The interaction between NCG and a droplet caused by gas enrichment near the solid surface is considered to explain the droplet wetting state during the condensation process. Finally, the disappearance mechanism of the flooding mode on the nanostructured surface under a large amount of NCG is clarified from the nanoscale, which could encourage a clear understanding of the NCG effect on dropwise condensation heat transfer on nanostructured superhydrophobic surfaces.

Failure and Recovery of Droplet Nucleation and Growth on Damaged Nanostructures: A Molecular Dynamics Study

The condensate flooding during dropwise condensation causes serious deterioration in heat transfer performance. In this study, the three-dimensional large-scale molecular dynamics simulation is carried out to investigate the droplet state transition from local flooding mode to Wenzel or from Wenzel to Cassie due to the droplet coalescence under the effect of nanostructure size. In particular, the effect of nanostructure breakage on droplet nucleation and growth is discussed to reveal the mechanism of dropwise condensation heat transfer deterioration. As a potential solution, the lubricant-impregnated surface is proposed to recover the preferred Cassie state by regulating the dynamic wetting characteristics of droplets, and thus the detrimental effect of nanostructure breakage could be effectively avoided.

Dynamic Wettability on the Lubricant-Impregnated Surface: From Nucleation to Growth and Coalescence

The surface dynamic wettability during droplet nucleation and growth involved with phase change is different from the static wettability formed from a sessile drop. Revealing this dynamic wettability of the lubricant-impregnated surfaces (LISs) and identification of the consistency between the wettability during condensation and the static wettability are of significant importance. In this study, we investigated condensation of water droplets on LISs using molecular dynamics simulations. All possible morphologies on LISs were investigated considering the effects of interfacial tension and lubricant thickness. The exploration of droplet behaviors from nucleation to growth and coalescence revealed four nucleation mechanisms and six growth modes. The lubricant was observed to be beneficial for the formation of droplets and maintaining dropwise condensation mode. The present investigation also established that the consistency between the wettability during condensation and the static wettability was determined by the solid-water-oil interface and the lubricant thickness. A map was proposed which helps in deciding whether the wettability during condensation is the same as the static wettability on LIS.

Design of Chemical Surface Treatment for Laser-Textured Metal Alloys to Achieve Extreme Wetting Behavior

Extreme wetting activities of laser-textured metal alloys have received significant interest due to their superior performance in a wide range of commercial applications and fundamental research studies. Fundamentally, extreme wettability of structured metal alloys depends on both the surface structure and surface chemistry. However, compared with the generation of physical topology on the surface, the role of surface chemistry is less explored for the laser texturing processes of metal alloys to tune the wettability. This work introduces a systematic design approach to modify the surface chemistry of laser textured metal alloys to achieve various extreme wettabilities, including superhydrophobicity/superoleophobicity, superhydrophilicity/superoleophilicity, and coexistence of superoleophobicity and superhydrophilicity. Microscale trenches are first created on the aluminum alloy 6061 surfaces by nanosecond pulse laser surface texturing. Subsequently, the textured surface is immersion-treated in several chemical solutions to attach target functional groups on the surface to achieve the final extreme wettability. Anchoring fluorinated groups (-CF₂- and -CF₃) with very low dispersive and nondispersive surface energy leads to superoleophobicity and superhydrophobicity, resulting in repelling both water and diiodomethane. Attachment of the polar nitrile (-C≡N) group with very high nondispersive and high dispersive surface energy achieves superhydrophilicity and superoleophilicity by drawing water and diiodomethane molecules in the laser-textured capillaries. At last, anchoring fluorinated groups (-CF₂- and -CF₃) and polar sodium carboxylate (-COONa) together leads to very low dispersive and very high nondispersive surface energy components. It results in the coexistence of superoleophobicity and superhydrophilicity, where the treated surface attracts water but repels diiodomethane.

Phosphonium Ionic Liquid-Infused Poly(vinyl chloride) Surfaces Possessing Potent Antifouling Properties

Microbial fouling is a costly issue, which impacts a wide range of industries, such as healthcare, food processing, and construction industries, and improved strategies to reduce the impact of fouling are urgently required. Slippery liquid-infused porous surfaces (SLIPSs) have recently been developed as a bioinspired approach to prevent antifouling. Here, we report the development of slippery, superhydrophilic surfaces by infusing roughened poly(vinyl chloride) (PVC) substrates with phosphonium ionic liquids (PILs). These surfaces were capable of reducing viable bacterial adherence by Staphylococcus aureus and Pseudomonas aeruginosa by >6 log10 cfu mL-1 after 24 h under static conditions relative to control PVC. Furthermore, we report the potential of a series of asymmetric quaternary alkyl PILs with varying alkyl chain lengths (C4-C18) and counteranions to act as antimicrobial agents against both Gram +ve and Gram -ve bacteria and illustrate their potential as antimicrobial alternatives to traditional fluorinated lubricants commonly used in the synthesis of SLIPSs.

Brushed lubricant-impregnated surfaces (BLIS) for long-lasting high condensation heat transfer

Recently, lubricant-impregnated surfaces (LIS) have emerged as a promising condenser surface by facilitating the removal of condensates from the surface. However, LIS has the critical limitation in that lubricant oil is depleted along with the removal of condensates. Such oil depletion is significantly aggravated under high condensation heat transfer. Here we propose a brushed LIS (BLIS) that can allow the application of LIS under high condensation heat transfer indefinitely by overcoming the previous oil depletion limit. In BLIS, a brush replenishes the depleted oil via physical contact with the rotational tube, while oil is continuously supplied to the brush by capillarity. In addition, BLIS helps enhance heat transfer performance with additional route to droplet removal by brush sweeping. By applying BLIS, we maintain the stable dropwise condensation mode for > 48 hours under high supersaturation levels along with up to 61% heat transfer enhancement compared to hydrophobic surfaces.

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

In this work, we use molecular dynamics (MD) simulations to investigate the dependences of formation and transition of surface condensation mode on wettability (β) and vapor-to-surface temperature difference (ΔT). We build a map of different surface condensation modes against β and ΔT based on plenty of MD simulation results and reveal five formation mechanisms and two transition mechanisms. At low β and ΔT, the high free energy barrier (ΔG*) prevents any surface clusters from surviving, therefore no-condensation (NC) is observed. The formation of dropwise condensation (DWC) could evolve from either nucleation or film rupture. Similarly, the formation of filmwise condensation (FWC) could evolve from either nucleation or the adsorption-induced film. The transition between NC and DWC is determined by ΔG* according to classical nucleation theory. The transition between DWC and FWC depends on the stability of condensate film; there emerges the competition between the trend that the uneven condensate film contracts and ruptures to droplets favored by lower β and the trend that the uneven condensate film continues growing promoted by higher ΔT. We finally present a schematic overview of all of the mechanisms revealed for a better understanding of the physical phenomenon of the surface condensation mode.

Droplet Morphology and Mobility on Lubricant-Impregnated Surfaces: A Molecular Dynamics Study

Slippery liquid-infused porous surfaces (SLIPS) are gaining remarkable attention and have advanced performance in many fields. Although all SLIPS are related to lubricant-impregnation within nano/microstructures on a surface, they differ in many aspects, such as the morphology of droplets, the state of cloaking, the wetting edge, and the lubricant thickness. Requirements of the droplet morphology on SLIPS might change according to a specific application. A molecular-dynamics-based numerical model that can correctly simulate SLIPS is developed and is validated by comparing against the theoretical predictions for all possible stable states for a given droplet, lubricant, and solid surface. On the basis of this model, a detailed analysis of the equilibrium states is conducted. In particular, we discover that the four possible stable states on SLIPS predicted by theoretical studies can be extended to eight states by considering the effects of lubricant thickness and surface geometry in addition to the interfacial tension and surface wettability. These findings could be used to determine the conditions under which a thermodynamically stable state exists on SLIPS. The dynamic behavior of a nanodroplet on SLIPS is also studied, which provides insight into how a proper increase in the lubricant thickness might increase the sliding velocity. The above findings and developed model are expected to provide significant guidelines for designing SLIPS.