Geometry of the vapor layer under a leidenfrost drop

Toward vanishing droplet friction on repellent surfaces

Superhydrophobic surfaces are often seen as frictionless materials, on which water is highly mobile. Understanding the nature of friction for such water-repellent systems is central to further minimize resistance to motion and energy loss in applications. For slowly moving drops, contact-line friction has been generally considered dominant on slippery superhydrophobic surfaces. Here, we show that this general rule applies only at very low speed. Using a micropipette force sensor in an oscillating mode, we measure the friction of water drops approaching or even equaling zero contact-line friction. We evidence that dissipation then mainly stems from the viscous shearing of the air film (plastron) trapped under the liquid. Because this force is velocity dependent, it can become a serious drag on surfaces that look highly slippery from quasi-static tests. The plastron thickness is found to be the key parameter that enables the control of this special friction, which is useful information for designing the next generation of ultraslippery water-repellent coatings.

Thermal Antibubbles: When Thermalization of Encapsulated Leidenfrost Drops Matters

Antibubbles are ephemeral objects composed of a liquid drop encapsulated by a thin gas shell immersed in a liquid medium. When the drop is made of a volatile liquid and the medium is superheated, the gas shell inflates at a rate governed by the evaporation flux from the drop. This thermal process represents an alternate strategy for delaying the antibubble collapse. We model the dynamics of such "thermal" antibubbles by incorporating to the film drainage equation the heat-transfer-limited evaporation of the drop, which nourishes the gas shell with vapor, as for Leidenfrost drops. We demonstrate that the inflation of the gas shell is drastically inhibited by the thermalization of the initially colder drop. Because of this thermalization effect, smaller drops evaporate much faster than larger ones.

Modeling Leidenfrost Levitation of Soft Elastic Solids

The elastic Leidenfrost effect occurs when a vaporizable soft solid is lowered onto a hot surface. Evaporative flow couples to elastic deformation, giving spontaneous bouncing or steady-state floating. The effect embodies an unexplored interplay between thermodynamics, elasticity, and lubrication: despite being observed, its basic theoretical description remains a challenge. Here, we provide a theory of elastic Leidenfrost floating. As weight increases, a rigid solid sits closer to the hot surface. By contrast, we discover an elasticity-dominated regime where the heavier the solid, the higher it floats. This geometry-governed behavior is reminiscent of the dynamics of large liquid Leidenfrost drops. We show that this elastic regime is characterized by Hertzian behavior of the solid's underbelly and derive how the float height scales with materials parameters. Introducing a dimensionless elastic Leidenfrost number, we capture the crossover between rigid and Hertzian behavior. Our results provide theoretical underpinning for recent experiments, and point to the design of novel soft machines.

Spontaneous Takeoff of Single Sulfur Nanoparticles during Sublimation Studied by Dark-Field Microscopy

The Leidenfrost effect describes a fascinating phenomenon in which a liquid droplet, when deposited onto a very hot substrate, will levitate on its own vapor layer and undergo frictionless movements. Driven by the significant implications for heat transfer engineering and drag reduction, intensive efforts have been made to understand, manipulate, and utilize the Leidenfrost effect on macrosized objects with a typical size of millimeters. The Leidenfrost effect of nanosized objects, however, remains unexplored. Herein, we report on an unprecedented Leidenfrost effect of single nanosized sulfur particles at room temperature. It was discovered when advanced dark-field optical microscopy was employed to monitor the dynamic sublimation process of single sulfur nanoparticles sitting on a flat substrate. Despite the phenomenological similarity, including the vapor-cushion-induced levitation and the extended lifetime, the Leidenfrost effect at the nanoscale exhibited two extraordinary features that were obviously distinct from its macroscopic counterpart. First, there was a critical size below which single sulfur nanoparticles began to levitate. Second, levitation occurred in the absence of the temperature difference between the nanoparticle and the substrate, which was barely possible for macroscopic objects and underscored the value of bridging the gap connecting the Leidenfrost effect and nanoscience. The sublimation-triggered spontaneous takeoff of single sulfur nanoparticles shed new light on its further applications, such as nanoflight.

Freezing-induced wetting transitions on superhydrophobic surfaces

Supercooled droplet freezing on surfaces occurs frequently in nature and industry, often adversely affecting the efficiency and reliability of technological processes. The ability of superhydrophobic surfaces to rapidly shed water and reduce ice adhesion make them promising candidates for resistance to icing. However, the effect of supercooled droplet freezing-with its inherent rapid local heating and explosive vaporization-on the evolution of droplet-substrate interactions, and the resulting implications for the design of icephobic surfaces, are little explored. Here we investigate the freezing of supercooled droplets resting on engineered textured surfaces. On the basis of investigations in which freezing is induced by evacuation of the atmosphere, we determine the surface properties required to promote ice self-expulsion and, simultaneously, identify two mechanisms through which repellency falters. We elucidate these outcomes by balancing (anti-)wetting surface forces with those triggered by recalescent freezing phenomena and demonstrate rationally designed textures to promote ice expulsion. Finally, we consider the complementary case of freezing at atmospheric pressure and subzero temperature, where we observe bottom-up ice suffusion within the surface texture. We then assemble a rational framework for the phenomenology of ice adhesion of supercooled droplets throughout freezing, informing ice-repellent surface design across the phase diagram.

Interfacial design for detection of a few molecules

Major advances in molecular detection are being driven by goals associated with the development of methods that are amenable to miniaturization and automation, and that have high sensitivity and low interference. The new detection methods are confronted by many interfacial issues, which when properly addressed can lead to improved performance. One interfacial property, special wettability, can facilitate precise delivery and local enrichment of molecules to sensing elements. This review summarizes applications of unique features of special wettability in molecular detection including (1) chemical and electrochemical reactions in anchored microdroplets on superwetting surfaces, (2) enrichment of analytes and active materials at low contact areas between droplets and superwetting surfaces, (3) complete opposite affinities of superwetting surfaces toward nonpolar/polar solutes and oil/water phases, and (4) directional droplet transportation on asymmetric superwetting surfaces. The challenges and opportunities that exist in design and applications of special wettability in interfacial delivery and enrichment for detection of a few molecules are also discussed.

Highly Efficient and Controlled Fabrication of Supraparticles by Leidenfrost Phenomenon

Supraparticles (SPs) are agglomerates of smaller particles, which show promising applications in catalysis, sensing, and so forth. Preparation of SPs with controlled sizes, components, and structures in an efficient, scalable, and environmentally friendly way has become an urgent demand for the development of SPs. Herein, a method to fabricate SPs based on the Leidenfrost phenomenon is described. By dropping a nano-/microparticle dispersion on a metal plate at the Leidenfrost temperature (T_LF) or higher, the solvent evaporates quickly, and SPs can be formed within 1 min. To understand the influence of various factors on the properties of SPs, and also to optimize the fabrication of SPs, the effects of metal surface roughness and primary particle concentration on T_LF were carefully observed. Plates with a higher roughness as well as a higher primary particle concentration could trigger a lower T_LF. Combining the regulation of composition and volume of the droplets, SPs with different sizes, compositions, and structures were precisely fabricated. Furthermore, highly porous titanium dioxide (TiO₂) SPs with enhanced photocatalytic performance were fabricated via this method, showing the merits of the method in practical applications. This simple, efficient, and green method provides a new approach for controlled and large-scale fabrication of SPs with various functions.

Droplet Bouncing: Fundamentals, Regulations, and Applications

Droplet impact is a ubiquitous phenomenon in nature, daily life, and industrial processes. It is thus crucial to tune the impact outcomes for various applications. As a special outcome of droplet impact, the bouncing of droplets keeps the form of the droplets after the impact and minimizes the energy loss during the impact, being beneficial in many applications. A unified understanding of droplet bouncing is in high demand for effective development of new techniques to serve applications. This review shows the fundamentals, regulations, and applications of millimeter-sized droplet bouncing on solid surfaces and same/miscible liquids (liquid pool and another droplet). Regulation methods and current applications are summarized, and potential directions are proposed.

Boiling Transitions During Droplet Contact on Superheated Nano/Micro-Structured Surfaces

Manipulating surface topography is one of the most promising strategies for increasing the efficiency of numerous industrial processes involving droplet contact with superheated surfaces. In such scenarios, the droplets may immediately boil upon contact, splash and boil, or could levitate on their own vapor in the Leidenfrost state. In this work, we report the outcomes of water droplets coming in gentle contact with designed nano/microtextured surfaces at a wide range of temperatures as observed using high-speed optical and X-ray imaging. We report a paradoxical increase in the Leidenfrost temperature (T_LFP) as the texture spacing is reduced below a critical value (∼10 μm) that represents a minima in T_LFP. Although droplets on such textured solids appear to boil upon contact, our studies suggest that their behavior is dominated by hydrodynamic instabilities implying that the increase in T_LFP may not necessarily lead to enhanced heat transfer. On such surfaces, the droplets display a new regime characterized by splashing accompanied by a vapor jet penetrating through the droplets before they transition to the Leidenfrost state. We provide a comprehensive map of boiling behavior of droplets over a wide range of texture spacings that may have significant implications toward applications such as electronics cooling, spray cooling, nuclear reactor safety, and containment of fire calamities.

Inhibiting the Leidenfrost effect above 1,000 °C for sustained thermal cooling

The Leidenfrost effect, namely the levitation of drops on hot solids¹, is known to deteriorate heat transfer at high temperature². The Leidenfrost point can be elevated by texturing materials to favour the solid-liquid contact^2-10 and by arranging channels at the surface to decouple the wetting phenomena from the vapour dynamics³. However, maximizing both the Leidenfrost point and thermal cooling across a wide range of temperatures can be mutually exclusive^3,7,8. Here we report a rational design of structured thermal armours that inhibit the Leidenfrost effect up to 1,150 °C, that is, 600 °C more than previously attained, yet preserving heat transfer. Our design consists of steel pillars serving as thermal bridges, an embedded insulating membrane that wicks and spreads the liquid and U-shaped channels for vapour evacuation. The coexistence of materials with contrasting thermal and geometrical properties cooperatively transforms normally uniform temperatures into non-uniform ones, generates lateral wicking at all temperatures and enhances thermal cooling. Structured thermal armours are limited only by their melting point, rather than by a failure in the design. The material can be made flexible, and thus attached to substrates otherwise challenging to structure. Our strategy holds the potential to enable the implementation of efficient water cooling at ultra-high solid temperatures, which is, to date, an uncharted property.

Thermophobic Leidenfrost

We report that a volatile liquid deposited on a hot substrate with a gradient of temperature does not only levitate (Leidenfrost effect), but also spontaneously accelerates to the cold. This thermophobic effect is also observed with sublimating solids, and we attribute it to the ability of temperature differences to tilt (slightly) the base of the "object", which induces a horizontal component to the levitating force. This scenario is tested by varying the drop size (with which the acceleration increases) and the substrate temperature (with which the acceleration decreases), showing that the effect can be used to control, guide and possibly trap the elusive Leidenfrost drops.

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.

Levitation of fizzy drops

As first described by Leidenfrost, liquid droplets levitate over their own vapor when placed on a sufficiently hot substrate. The Leidenfrost effect not only confers remarkable properties such as mechanical and thermal insulation, zero adhesion, and extreme mobility but also requires a high energetic thermal cost. We describe here a previously unexplored approach using active liquids able to sustain levitation in the absence of any external forcing at ambient temperature. We focus on the particular case of carbonated water placed on a superhydrophobic solid and demonstrate how millimetric fizzy drops self-generate a gas cushion that provides levitation on time scales on the order of a minute. Last, we generalize this new regime to different kinds of chemically reactive droplets able to jump from the Cassie-Baxter state to a levitating regime, paving the way to the levitation of nonvolatile liquids.

Erratum: Leidenfrost effect: Accurate drop shape modeling and refined scaling laws [Phys. Rev. E 90, 053011 (2014)]

This corrects the article DOI: 10.1103/PhysRevE.90.053011.

Leidenfrost droplet trampolining

A liquid droplet dispensed over a sufficiently hot surface does not make contact but instead hovers on a cushion of its own self-generated vapor. Since its discovery in 1756, this so-called Leidenfrost effect has been intensively studied. Here we report a remarkable self-propulsion mechanism of Leidenfrost droplets against gravity, that we term Leidenfrost droplet trampolining. Leidenfrost droplets gently deposited on fully rigid surfaces experience self-induced spontaneous oscillations and start to gradually bounce from an initial resting altitude to increasing heights, thereby violating the traditionally accepted Leidenfrost equilibrium. We found that the continuously draining vapor cushion initiates and fuels Leidenfrost trampolining by inducing ripples on the droplet bottom surface, which translate into pressure oscillations and induce self-sustained periodic vertical droplet bouncing over a broad range of experimental conditions.

The classic Leidenfrost phenomenon is familiar, yet its physics is rather complex. Graeber et al. observe the unexpected development of repeated hopping of a droplet trampolining on its own vapor cushion on a hot plate and show under which conditions this self-initiated motion occurs.

On explosive boiling of a multicomponent Leidenfrost drop

The gasification of multicomponent fuel drops is relevant in various energy-related technologies. An interesting phenomenon associated with this process is the self-induced explosion of the drop, producing a multitude of smaller secondary droplets, which promotes overall fuel atomization and, consequently, improves the combustion efficiency and reduces emissions of liquid-fueled engines. Here, we study a unique explosive gasification process of a tricomponent droplet consisting of water, ethanol, and oil ("ouzo"), by high-speed monitoring of the entire gasification event taking place in the well-controlled, levitated Leidenfrost state over a superheated plate. It is observed that the preferential evaporation of the most volatile component, ethanol, triggers nucleation of the oil microdroplets/nanodroplets in the remaining drop, which, consequently, becomes an opaque oil-in-water microemulsion. The tiny oil droplets subsequently coalesce into a large one, which, in turn, wraps around the remnant water. Because of the encapsulating oil layer, the droplet can no longer produce enough vapor for its levitation, and, thus, falls and contacts the superheated surface. The direct thermal contact leads to vapor bubble formation inside the drop and consequently drop explosion in the final stage.

Interfacial Crystallization within Liquid Marbles

We report interfacial crystallization in the droplets of saline solutions placed on superhydrophobic surfaces and liquid marbles filled with the saline. Evaporation of saline droplets deposited on superhydrophobic surface resulted in the formation of cup-shaped millimeter-scaled residues. The formation of the cup-like deposit is reasonably explained within the framework of the theory of the coffee-stain effect, namely, the rate of heterogeneous crystallization along the contact line of the droplet is significantly higher than in the droplet bulk. Crystallization within evaporated saline marbles coated with lycopodium particles depends strongly on the evaporation rate. Rapidly evaporated saline marbles yielded dented shells built of a mixture of colloidal particles and NaCl crystals. We relate the formation of these shells to the interfacial crystallization promoted by hydrophobic particles coating the marbles, accompanied with the upward convection flows supplying the saline to the particles, serving as the centers of interfacial crystallization. Convective flows prevail over the diffusion mass transport for the saline marbles heated from below.

Oscillation and self-propulsion of Leidenfrost droplets enclosed in cylindrical cavities

Leidenfrost droplets can be considered as soft engines capable of directly transforming heat into mechanical energy. Despite remarkable advancements in understanding the propulsion of Leidenfrost droplets on asymmetric structures, the complex dynamics of droplets in enclosed structures is not fully understood. To address this fundamental gap, we investigated the dynamics of Leidenfrost droplets restricted by metal disks. The disk alters the accumulation and release of the vapour generated by the droplet, and substantially changes its dynamic characteristics. Our experiments reveal the formation of oscillating multi-lobed structures when restricting the droplet within a disk. In comparison, patterning offset radial grooves on the surface of the disk rectifies the vapour flow and facilitates the self-propulsion of the droplet along the edge of the disk. Our work offers opportunities for developing soft and short-living actuators, which can operate at high temperatures.

Film levitation and central jet of droplet impact on nanotube surface at superheated conditions

Influences of surface nanotubes at high temperatures are investigated on droplet impact dynamics and Leidenfrost effect. Five distinct regimes of impact droplets are found on the nanotube surface, including contact boiling, film levitation, central jet levitation, central jet, and Leidenfrost phenomenon. The regimes of film levitation, central jet levitation, and central jet are characterized by either film levitation and/or liquid central jet. The regime of Leidenfrost phenomenon is characterized by droplet bounce-off behavior free of any liquid jets. Film levitation is driven by the vaporization of two parts of the droplet, with one as the droplet bottom layer over the contact area above the nanotube structure, and the other as the hemiwicking liquid in nanotubes. Both the vaporization is impaired by increasing the surface temperature, which is attributed to the reduced contact time and less extent of spread of the droplet at a higher surface temperature. The central jet phenomenon is driven by the vapor stream produced by hemiwicking liquid in the central area upon impact. It is enhanced and then suppressed by elevating the surface temperature, resulting from the collective effects of the vapor pressure in nanotubes which increases with the surface temperature, and the cross-sectional area of the vapor stream, which increases and then decreases with the surface temperature. At a high Weber number, the Leidenfrost temperature can be increased by 125^{∘}C on the nanotube surface, implying a great potential in heat transfer enhancement for droplet-based applications.

Drop impact on hot plates: contact times, lift-off and the lamella rupture

When a liquid drop impacts on a heated substrate, it can remain deposited, or violently boil in contact, or lift off with or without ever touching the surface. The latter is known as the Leidenfrost effect. The duration and area of the liquid-substrate contact are highly relevant for the heat transfer, as well as other effects such as corrosion. However, most experimental studies rely on side view imaging to determine contact times, and those are often mixed with the time until the drop lifts off from the substrate. Here, we develop and validate a reliable method of contact time determination using high-speed X-ray imaging and total internal reflection imaging. We exemplarily compare contact and lift-off times on flat silicon and sapphire substrates. We show that drops can rebound even without formation of a complete vapor layer, with a wide range of lift-off times. On sapphire, we find a local minimum of lift-off times that is much shorter than expected from capillary rebound in the comparatively low-temperature regime of transition boiling/thermal atomization. We elucidate the underlying mechanism related to spontaneous rupture of the lamella and receding of the contact area.

Air layer during the impact of droplets on heated substrates

When a droplet impacts on a substrate, the air underneath the droplet is compressed to form an air layer of a dimple shape before the droplet wets the substrate. This air layer is important to the impact dynamics, and many studies have been performed to investigate the air layer during the impact process on unheated substrates. In this experimental study of the air layer, our results reveal that the air layer is profoundly affected by the substrate temperature, even if the substrate temperature is below the boiling point of the droplet fluid. We use high-speed imaging and color interferometry to measure the air layer with nanometer accuracy. The results show that the thickness of the air layer increases with increasing the substrate temperature. Compared with the impact of the droplet on the unheated substrate, the average thickness of the air layer on the heated substrate at 70 °C is about 12% thicker. This will affect the subsequent bubble entrapment, which is an important feature of the impact dynamics. A simplified model is proposed to consider the heat transfer in the air layer. Additionally, the effects of the Weber number, the fluid viscosity, and the size of the droplet on the air layer are also analyzed. This study sheds light on controlling the impact dynamics of droplets by adjusting the substrate temperature.

Rectification of Mobile Leidenfrost Droplets by Planar Ratchets

The self-transportation of mobile Leidenfrost droplets with well-defined direction and velocity on millimetric ratchets is one of the most representative and spectacular phenomena in droplet dynamics. Despite extensive progress in the ability to control the spatiotemporal propagation of droplets, it remains elusive how the individual ratchet units, as well as the interactions within their arrays, are translated into the collective droplet dynamics. Here, simple planar ratchets characterized by uniform height normal to the surface are designed. It is revealed that on planar ratchets, the transport dynamics of Leidenfrost droplets is dependent not only on individual units, but also on the elegant coordination within their arrays dictated by their topography. The design of planar ratchets enriches the fundamental understanding of how the surface topography is translated into dynamic and collective droplet transport behaviors, and also imparts higher applicability in microelectromechanical system based fluidic devices.

Tuning Contact Line Dynamics and Deposition Patterns in Volatile Liquid Mixtures

The spreading of a pure, volatile liquid on a wettable substrate has been studied in extensive detail. Here we show that the addition of a miscible, nonvolatile liquid can strongly alter the contact line dynamics and the final liquid deposition pattern. We observe two distinct regimes of behavior depending on the relative strength of solutal Marangoni forces and surface wetting. Fingerlike instabilities precede the deposition of a submicron thick film for large Marangoni forces and small solute contact angles, whereas isolated pearl-like drops emerge and are deposited in quasicrystalline patterns for small Marangoni forces and large solute contact angles. This behavior can be tuned by directly varying the contact angle of the solute liquid on the solid substrate.

The cold Leidenfrost regime

Superhydrophobicity (observed at room temperature) and Leidenfrost phenomenon (observed on very hot solids) are classical examples of nonwetting surfaces. It was found that combining the two effects by heating water-repellent materials leads to a marked yet unexplained decrease of the Leidenfrost temperature of water. We discuss here how heat enhances superhydrophobicity by favoring a "cold Leidenfrost regime" where water adhesion becomes nonmeasurable even at moderate substrate temperature. Heat is found to induce contradictory effects (sticking due to vapor condensation, and lift due to the spreading of vapor patches), which is eventually shown to be controllable by the solid surface texture. The transition to the levitating Leidenfrost regime is observed to be continuous as a function of temperature, contrasting with the transition on common solids.

Explosive bouncing on heated silicon surfaces under low ambient pressure

Droplet impingement on heated surfaces has been investigated by varying the surface textures, temperature, and droplet properties with demonstration of various phenomenological behaviors, such as evaporation, boiling, splashing, and Leidenfrost bouncing. However, the ambient pressure dependence has not been well explored, especially for ambient pressures lower than 5 kPa. By examining the ambient pressure (from 0.2 to 20 kPa) and surface temperature (from 20 to 200 °C) simultaneously, we found a novel explosive bouncing behavior which is different from Leidenfrost bouncing and only occurs at extremely low ambient pressure (≤6 kPa). Through experimental validation and mechanical analysis, we found that the explosive bouncing is caused by the dramatic explosion of the local vapor bubble and reducing the ambient pressure benefits the formation and explosion of the vapor bubble.

Final fate of a Leidenfrost droplet: Explosion or takeoff

When a liquid droplet is placed on a very hot solid, it levitates on its own vapor layer, a phenomenon called the Leidenfrost effect. Although the mechanisms governing the droplet's levitation have been explored, not much is known about the fate of the Leidenfrost droplet. Here we report on the final stages of evaporation of Leidenfrost droplets. While initially small droplets tend to take off, unexpectedly, the initially large ones explode with a crack sound. We interpret these in the context of unavoidable droplet contaminants, which accumulate at the droplet-air interface, resulting in reduced evaporation rate, and contact with the substrate. We validate this hypothesis by introducing controlled amounts of microparticles and reveal a universal 1/3-scaling law for the dimensionless explosion radius versus contaminant fraction. Our findings open up new opportunities for controlling the duration and rate of Leidenfrost heat transfer and propulsion by tuning the droplet's size and contamination.

Biological and Engineered Topological Droplet Rectifiers

The power of the directional and spontaneous transport of liquid droplets is revealed through ubiquitous biological processes and numerous practical applications, where droplets are rectified to achieve preferential functions. Despite extensive progress, the fundamental understanding and the ability to exploit new strategies to rectify droplet transport remain elusive. Here, the latest progress in the fundamental understanding as well as the development of engineered droplet rectifiers that impart superior performance in a wide variety of working conditions, ranging from low temperature, ambient temperature, to high temperature, is discussed. For the first time, a phase diagram is formulated that naturally connects the droplet dynamics, including droplet formation modes, length scales, and phase states, with environmental conditions. Parallel approaches are then taken to discuss the basic physical mechanisms underlying biological droplet rectifiers, and a variety of strategies and manufacturing routes for the development of robust artificial droplet rectifiers. Finally, perspectives on how to create novel man-made rectifiers with functionalities beyond natural counterparts are presented.

Laser-induced subwavelength structures by microdroplet superlens

Nanoscale patterns on rigid or flexible substrates are of considerable interest in modern nanophotonics and optoelectronics devices. Subwavelength structures are produced in this study by using a laser beam and microdroplets that carry nanoparticles to the deposition substrate. These droplets are generated from an aqueous suspension of nanoparticles by electrospray and dispensed through a conical hollow laser beam so that laser-droplet interactions occur immediately above the substrate surface. Each microdroplet serves the dual role as a nanoparticle carrier to the substrate and as a superlens for focusing the laser beam to a subwavelength diameter. This focused beam vaporizes the droplet and sinters the nanoparticles on the substrate. The deposition of subwavelength nanostructures and thin films on a silicon wafer are demonstrated in this paper. This process may be applied to produce novel nanophotonics and electronics devices involving a variety of subwavelength patterns including an ordered array of semiconductor nanoparticles.

High jump of impinged droplets before Leidenfrost state

Unlike the traditionally reported Leidenfrost droplet which only floats on a thin film of vapor, we observe a prominent jump of the impinged droplets in the transition from the contact boiling to the Leidenfrost state. The vapor generation between the droplet and the substrate is vigorous enough to propel the spreading droplet pancake to an anomalous height. The maximum repellent height can be treated as an index of the total transferred energy. Counterintuitively, a stronger vaporization and a higher jump can be generated in the conditions normally considered to be unfavorable to heat transfer, such as a lower substrate temperature, a lower droplet impact velocity, a higher droplet temperature, or a lower thermal conductivity of the deposition on the substrate. Since the total transferred energy is the accumulation of the instantaneous heat flux during the droplet contacting with the substrate, it can be deduced that a longer contact time period is secured in the case of a lower instantaneous heat flux. The inference is supported by our experimental observations. Moreover, the phase diagrams describe the characteristics of the high repellency under different substrate temperatures, droplet subcooling temperatures, and Weber numbers. It allows us to manipulate the droplet jump for the relative applications.

High-speed X-ray imaging of the Leidenfrost collapse

The Leidenfrost layer is characterized by an insulating vapor film between a heated surface and an ambient liquid. The collapse of this film has been canonically theorized to occur from an interfacial instability between the liquid and vapor phases. The interfacial instability alone, however, is insufficient to explain the known influence of the surface on the film collapse process. In this work, we provide visual evidence for two key mechanisms governing the film collapse: the interfacial instability, and the nucleation of vapor upon multiple non-terminal liquid-solid contacts. These results were obtained by implementing high-speed X-ray imaging of the film collapse on a heated sphere submerged in liquid-water. The X-ray images were synchronized with a second high-speed visible light camera and two thermocouples to provide insight into the film formation and film collapse processes. Lastly, the dynamic film thickness was quantified by analysis of the X-ray images. This helped assess the influence of surface roughness on the disruption of the film. The results of this work encourage further investigation into non-linear stability theory to consolidate the role of the surface on the liquid-vapor interface during the film collapse process.

Acoustic detection of electrostatic suppression of the Leidenfrost state

At high temperatures, a droplet can rest on a cushion of its vapor (the Leidenfrost effect). Application of an electric field across the vapor gap fundamentally eliminates the Leidenfrost state by attracting liquid towards the surface. This study uses acoustic signature tracking to study electrostatic suppression of the Leidenfrost state on solid and liquid surfaces. It is seen that the liquid-vapor instabilities that characterize suppression on solid surfaces can be detected acoustically. This can be the basis for objective measurements of the threshold voltage and frequency required for suppression. Acoustic analysis provides additional physical insights that would be challenging to obtain with other measurements. On liquid surfaces, the absence of an acoustic signal indicates a different suppression mechanism (instead of instabilities). Acoustic signature tracking can also detect various boiling patterns associated with electrostatically assisted quenching. Overall, this work highlights the benefits of acoustics as a tool to better understand electrostatic suppression of the Leidenfrost state, and the resulting heat transfer enhancement.

From Bouncing to Floating: The Leidenfrost Effect with Hydrogel Spheres

The Leidenfrost effect occurs when a liquid or stiff sublimable solid near a hot surface creates enough vapor beneath it to lift itself up and float. In contrast, vaporizable soft solids, e.g., hydrogels, have been shown to exhibit persistent bouncing-the elastic Leidenfrost effect. By carefully lowering hydrogel spheres towards a hot surface, we discover that they are also capable of floating. The bounce-to-float transition is controlled by the approach velocity and temperature, analogously to the "dynamic Leidenfrost effect." For the floating regime, we measure power-law scalings for the gap geometry, which we explain with a model that couples the vaporization rate to the spherical shape. Our results reveal that hydrogels are a promising pathway for controlling floating Leidenfrost objects through shape.

Dynamic Surface Wetting and Heat Transfer in a Droplet-Particle System of Less Than Unity Size Ratio

Dynamic surface wetting of particles in contact with droplet is a complex phenomenon ubiquitously encountered in many multiphase systems of industrial importance. In this study, we address this aspect by investigating impact behavior of a water droplet (diameter = 2.9 ± 0.1 mm) in the Weber number (We) range from ~4 to 104 on a stationary spherical brass particle (diameter = 10 mm) with and without heat transfer using a combination of high speed imaging and computational fluid dynamics (CFD) modeling approach. In cold state interactions (20°C), droplet exhibited oscillatory interfacial motion comprising periodic spreading and recoiling motion. Interactions involving heat transfer were studied in film boiling regime (350°C) and two outcomes were noted-droplet rebound and disintegration. A coupled Level Set and Volume of Fluid (VOF) approach based multiphase CFD model was utilized to predict the dynamic spread ratio and transient evolution of droplet shape during the interaction. To capture the complex contact line motion realistically, a continuous time varying profile of experimentally measured dynamic contact angles was used as a wall boundary condition for the cold interactions which provided good agreement with experimentally measured droplet spread ratio. In film boiling regime, droplet spread ratio was correlated to impact Weber number and a power law trend was obtained. Rebound and disintegration outcomes were characterized by the droplet-particle contact time. For simulating interactions in film boiling regime, a constant contact angle in the limit of super-hydrophobic surface was implemented in the CFD model to account for the apparent non-wetting effect due to vapor film formation at the contact area. A sensitivity analysis was performed involving three different contact angle boundary conditions (θ _s = 150, 160, and 170°) to represent the surface hydrophobicity. CFD model predicted interaction outcomes and droplet spread ratios were in reasonable agreement with the experiment at different impact Weber numbers. Increase in spherical surface heat flux and corresponding rise in droplet temperature at different impact Weber numbers were also quantified which showed an increasing trend up to a critical Weber number for droplet disintegration.

We -T classification of diesel fuel droplet impact regimes

A combined experimental and computational investigation of micrometric diesel droplets impacting on a heated aluminium substrate is presented. Dual view high-speed imaging has been employed to visualize the evolution of the impact process at various conditions. The parameters investigated include wall-surface temperature ranging from 140 to 400°C, impact Weber and Reynolds numbers of 19–490 and 141–827, respectively, and ambient pressure of 1 and 2 bar. Six possible post-impact regimes were identified, termed as Stick, Splash, Partial-Rebound, Rebound, Breakup-Rebound and Breakup-Stick , and plotted on the We-T map. Additionally, the temporal variation of the apparent dynamic contact angle and spreading factor have been determined as a function of the impact Weber number and surface temperature. Numerical simulations have also been performed using a two-phase flow model with interface capturing, phase-change and variable physical properties. Increased surface temperature resulted to increased maximum spreading diameter and induced quicker and stronger recoiling behaviour, mostly attributed to the change of liquid viscosity.

Leidenfrost Self-Rewetting Drops

As discovered by Leidenfrost, liquids placed on very hot solids levitate on a cushion of their own vapor. This is also called the calefaction phenomenon, a dynamical and transient effect, as vapor is injected below the liquid and pressed by the drop weight. To account for the film vapor, we consider the surface tension magnitude as well as the Marangoni effect (in particular the thermal one) which arise with imbalance of surface tension forces. For standard liquids, these forces contribute to amplify the thickness of the film layer and the levitation of the droplet. Our findings imply the ability of recent binary mixture liquids, called self-rewetting fluids, to reduce the vapor film thickness and demonstrate the powerful influence exerted by different binary mixtures to enhance the heat transfer at high temperature. Such self-rewetting fluids are presenting a high value of surface tension at high temperature, and in which the Marangoni forces are inversed as from critical temperature. We consider our assay to be a way for improvement in the high temperature mass cooling applications.

Electrostatic Suppression of the Leidenfrost State on Liquid Substrates

An applied electric field can fundamentally eliminate the Leidenfrost effect (formation of a vapor layer at the solid-liquid interface at high temperatures). This study analyzes electrostatic suppression of the Leidenfrost state on liquid substrates. Electrostatic suppression on silicone oil and Wood's metal (liquid alloy) is studied via experimentation, high-speed imaging, and analyses. It is seen that the nature of electrostatic suppression can be drastically different from that on a solid substrate. First, the Leidenfrost droplet completely penetrates into the silicone oil substrate and converts to a thin film under an electric field. This is due to the existence of an electric field inside the substrate and the deformability of the silicone oil interface. A completely different type of suppression is observed for Wood's metal and solid substrates, which have low deformability and lack an electric field in the substrate. Second, the minimum voltage to trigger suppression is significantly lower on silicone oil when compared to Wood's metal and solid substrates. Fundamental differences between these transitions are analyzed, and a multiphysics analytical model is developed to predict the vapor layer thickness on deformable liquids. Overall, this study lays the foundation for further studies on electrostatic manipulation of the Leidenfrost state on liquids.

Superposition of Translational and Rotational Motions under Self-Propulsion of Liquid Marbles Filled with Aqueous Solutions of Camphor

Self-locomotion of liquid marbles, coated with lycopodium or fumed fluorosilica powder, filled with a saturated aqueous solution of camphor and placed on a water/vapor interface is reported. Self-propelled marbles demonstrated a complicated motion, representing a superposition of translational and rotational motions. Oscillations of the velocity of the center of mass and the angular velocity of marbles, occurring in the antiphase, were registered and explained qualitatively. Self-propulsion occurs because of the Marangoni solutocapillary flow inspired by the adsorption of camphor (evaporated from the liquid marble) by the water surface. Scaling laws describing translational and rotational motions are proposed and checked. The rotational motion of marbles arises from the asymmetry of the field of the Marangoni stresses because of the adsorption of camphor evaporated from marbles.

A simple economic and heat transfer analysis of the nanoparticles use

In this paper, a review of the impact of most common nanoparticles on the Leidenfrost temperature T_Leid in heat transfer applications is delivered. Moreover, a simple economic analysis of the nanoparticles use is proposed. When coolant is distilled water, T_Leid can range 150–220 °C; occasionally, it can even amount to over 400 °C. When the base liquid is modified by additives, considerable changes in the character of heat transfer are observed. Out of five nanofluids under consideration in this study, the best thermal effect (up to 50%) is obtained when Al₂O₃ nanofluid having particle sizes ~39 nm and volume concentration of 0.1% is used. Conversely, the fluid containing TiO₂ particles, 20–70 nm in size, seems to be the worst of the analysed fluid, giving only 7% heat transfer enhancement in comparison with water. However, when TiO₂ nanoparticles are far smaller, very good thermal effects are obtained (23–25%). In a majority of the cases analysed, the temperature that marks the onset of film boiling is inversely proportional to concentrations of nanoparticles, which is relevant from the economic standpoint.

Heat exchange between a bouncing drop and a superhydrophobic substrate

The ability to enhance or limit heat transfer between a surface and impacting drops is important in applications ranging from industrial spray cooling to the thermal regulation of animals in cold rain. When these surfaces are micro/nanotextured and hydrophobic, or superhydrophobic, an impacting drop can spread and recoil over trapped air pockets so quickly that it can completely bounce off the surface. It is expected that this short contact time limits heat transfer; however, the amount of heat exchanged and precise role of various parameters, such as the drop size, are unknown. Here, we demonstrate that the amount of heat exchanged between a millimeter-sized water drop and a superhydrophobic surface will be orders of magnitude less when the drop bounces than when it sticks. Through a combination of experiments and theory, we show that the heat transfer process on superhydrophobic surfaces is independent of the trapped gas. Instead, we find that, for a given spreading factor, the small fraction of heat transferred is controlled by two dimensionless groupings of physical parameters: one that relates the thermal properties of the drop and bulk substrate and the other that characterizes the relative thermal, inertial, and capillary dynamics of the drop.

Effect of surface topography and wettability on the Leidenfrost effect

When deposited on a superheated surface, a droplet can be levitated by its own vapour layer, a phenomenon that is referred to as the Leidenfrost effect. This dynamic effect has attracted interest for many potential applications, such as cooling, drag reduction and drop transport. A lot of effort has been paid to this mechanism over the past two and half centuries. Herein, we not only review the classical theories but also present the most recent theoretical advances in understanding the Leidenfrost effect. We first review the basic theories of the Leidenfrost effect, which mainly focuses on the relationship between the drop shape, vapour layer and lifetime. Then, the shift in the Leidenfrost point realized by fabricating special surface textures is introduced and the mechanisms behind this are analyzed. Furthermore, we present the reasons for the droplet transport in both classical Leidenfrost and pseudo-Leidenfrost regimes. Finally, the promising breakthroughs of the Leidenfrost effect are briefly addressed.

Decoupled Hierarchical Structures for Suppression of Leidenfrost Phenomenon

Thermal management of high temperature systems through cooling droplets is limited by the existence of the Leidenfrost point (LFP), at which the formation of a continuous vapor film between a hot solid and a cooling droplet diminishes the heat transfer rate. This limit results in a bottleneck for the advancement of the wide spectrum of systems including high-temperature power generation, electronics/photonics, reactors, and spacecraft. Despite a long time effort on development of surfaces for suppression of this phenomenon, this limit has only shifted to higher temperatures, but still exists. Here, we report a new multiscale decoupled hierarchical structure that suppress the Leidenfrost state and provide efficient heat dissipation at high temperatures. The architecture of these structures is composed of a nanomembrane assembled on top of a deep micropillar structure. This architecture allows to independently tune the involved forces and to suppress LFP. Once a cooling droplet contacts these surfaces, by rerouting the path of vapor flow, the cooling droplet remains attached to the hot solid substrates even at high temperatures (up to 570 °C) for heat dissipation with no existence of Leidenfrost phenomenon. These new surfaces offer unprecedented heat dissipation capacity at high temperatures (2 orders of magnitude higher than the other state-of-the-art surfaces). We envision that these surfaces open a new avenue in thermal management of high-temperature systems through spray cooling.

The impact of viscoplastic drops on a heated surface in the Leidenfrost regime

The impact morphology of viscoplastic drops on a heated surface in the Leidenfrost regime is investigated experimentally by high-speed imaging. In particular several important parameters which characterize the impact morphology (such as maximum spreading diameter, minimum retracting diameter and maximum bouncing height etc.) are measured by analysing the impact process, recorded using a high-speed camera. It is shown that as the yield stress grows, surface forces are no longer able to minimize the free surface of the drop, and the inertial deformation upon impact becomes permanent. For small values of the yield stress, the impact morphology of viscoplastic Leidenfrost drops is similar to that of Newtonian drops. These effects can be interpreted in terms of the Bingham-Capillary number, which compares the yield stress magnitude and the capillary (Laplace) pressure. These results suggest that the main contribution to drop rebound is due to surface forces, and not to the intrinsic elasticity of the vapour cushion between the drop and the surface, which is a major assumption in one of the existing models.

Jumps, somersaults, and symmetry breaking in Leidenfrost drops

When a droplet of water impacts a heated surface, the drop may be observed to bounce. Recently is has been found that small quantities (∼100 ppm) of polymer additives such as polyethylene oxide can significantly increase the maximum bouncing height of drops. This effect has been explained in terms of the reduction of energy dissipation caused by polymer additives during the drop retraction and rebound, resulting in higher mechanical energy available for bouncing. Here we demonstrate, by comparing three types of fluids (Newtonian, shear-thinning, and viscoelastic), that the total kinetic energy carried by low-viscosity Newtonian drops during retraction is partly transformed into rotational kinetic energy rather than dissipated when compared with high-viscosity or non-Newtonian drops. We also show that non-Newtonian effects play little role in the energy distribution during drop impact, while the main effect is due to the symmetry break observed during the retraction of low-viscosity drops.

The Evolution of Process Safety: Current Status and Future Direction

The advent of the industrial revolution in the nineteenth century increased the volume and variety of manufactured goods and enriched the quality of life for society as a whole. However, industrialization was also accompanied by new manufacturing and complex processes that brought about the use of hazardous chemicals and difficult-to-control operating conditions. Moreover, human-process-equipment interaction plus on-the-job learning resulted in further undesirable outcomes and associated consequences. These problems gave rise to many catastrophic process safety incidents that resulted in thousands of fatalities and injuries, losses of property, and environmental damages. These events led eventually to the necessity for a gradual development of a new multidisciplinary field, referred to as process safety. From its inception in the early 1970s to the current state of the art, process safety has come to represent a wide array of issues, including safety culture, process safety management systems, process safety engineering, loss prevention, risk assessment, risk management, and inherently safer technology. Governments and academic/research organizations have kept pace with regulatory programs and research initiatives, respectively. Understanding how major incidents impact regulations and contribute to industrial and academic technology development provides a firm foundation to address new challenges, and to continue applying science and engineering to develop and implement programs to keep hazardous materials within containment. Here the most significant incidents in terms of their impact on regulations and the overall development of the field of process safety are described.

Inverse Leidenfrost Effect: Levitating Drops on Liquid Nitrogen

We explore the interaction between a liquid drop (initially at room temperature) and a bath of liquid nitrogen. In this scenario, heat transfer occurs through film-boiling: a nitrogen vapor layer develops that may cause the drop to levitate at the bath surface. We report the phenomenology of this inverse Leidenfrost effect, investigating the effect of the drop size and density by using an aqueous solution of a tungsten salt to vary the drop density. We find that (depending on its size and density) a drop either levitates or instantaneously sinks into the bulk nitrogen. We begin by measuring the duration of the levitation as a function of the radius R and density ρd of the liquid drop. We find that the levitation time increases roughly linearly with drop radius but depends weakly on the drop density. However, for sufficiently large drops, R ≥ Rc(ρd), the drop sinks instantaneously; levitation does not occur. This sinking of a (relatively) hot droplet induces film-boiling, releasing a stream of vapor bubbles for a well-defined length of time. We study the duration of this immersed-drop bubbling finding similar scalings (but with different prefactors) to the levitating drop case. With these observations, we study the physical factors limiting the levitation and immersed-film-boiling times, proposing a simple model that explains the scalings observed for the duration of these phenomena, as well as the boundary of (R,ρd) parameter space that separates them.

Dynamic Leidenfrost Effect: Relevant Time and Length Scales

When a liquid droplet impacts a hot solid surface, enough vapor may be generated under it to prevent its contact with the solid. The minimum solid temperature for this so-called Leidenfrost effect to occur is termed the Leidenfrost temperature, or the dynamic Leidenfrost temperature when the droplet velocity is non-negligible. We observe the wetting or drying and the levitation dynamics of the droplet impacting on an (isothermal) smooth sapphire surface using high-speed total internal reflection imaging, which enables us to observe the droplet base up to about 100 nm above the substrate surface. By this method we are able to reveal the processes responsible for the transitional regime between the fully wetting and the fully levitated droplet as the solid temperature increases, thus shedding light on the characteristic time and length scales setting the dynamic Leidenfrost temperature for droplet impact on an isothermal substrate.