A single parameter can predict surfactant impairment of superhydrophobic drag reduction.

Recent experimental and computational investigations have shown that trace amounts of surfactants, unavoidable in practice, can critically impair the drag reduction of superhydrophobic surfaces (SHSs), by inducing Marangoni stresses at the air-liquid interface. However, predictive models for realistic SHS geometries do not yet exist, which has limited the understanding and mitigation of these adverse surfactant effects. To address this issue, we derive a model for laminar, three-dimensional flow over SHS gratings as a function of geometry and soluble surfactant properties, which together encompass 10 dimensionless groups. We establish that the grating length g is the key geometric parameter and predict that the ratio between actual and surfactant-free slip increases with g2. Guided by our model, we perform synergistic numerical simulations and microfluidic experiments, finding good agreement with the theory as we vary surfactant type and SHS geometry. Our model also enables the estimation, based on velocity measurements, of a priori unknown properties of surfactants inherently present in microfluidic systems. For SHSs, we show that surfactant effects can be predicted by a single parameter, representing the ratio between the grating length and the interface length scale beyond which the flow mobilizes the air-water interface. This mobilization length is more sensitive to the surfactant chemistry than to its concentration, such that even trace-level contaminants may significantly increase drag if they are highly surface active. These findings advance the fundamental understanding of realistic interfacial flows and provide practical strategies to maximize superhydrophobic drag reduction.

Traces of surfactants can severely limit the drag reduction of superhydrophobic surfaces.

Superhydrophobic surfaces (SHSs) have the potential to achieve large drag reduction for internal and external flow applications. However, experiments have shown inconsistent results, with many studies reporting significantly reduced performance. Recently, it has been proposed that surfactants, ubiquitous in flow applications, could be responsible by creating adverse Marangoni stresses. However, testing this hypothesis is challenging. Careful experiments with purified water already show large interfacial stresses and, paradoxically, adding surfactants yields barely measurable drag increases. To test the surfactant hypothesis while controlling surfactant concentrations with precision higher than can be achieved experimentally, we perform simulations inclusive of surfactant kinetics. These reveal that surfactant-induced stresses are significant at extremely low concentrations, potentially yielding a no-slip boundary condition on the air-water interface (the "plastron") for surfactant concentrations below typical environmental values. These stresses decrease as the stream-wise distance between plastron stagnation points increases. We perform microchannel experiments with SHSs consisting of stream-wise parallel gratings, which confirm this numerical prediction, while showing near-plastron velocities significantly slower than standard surfactant-free predictions. In addition, we introduce an unsteady test of surfactant effects. When we rapidly remove the driving pressure following a loading phase, a backflow develops at the plastron, which can only be explained by surfactant gradients formed in the loading phase. This demonstrates the significance of surfactants in deteriorating drag reduction and thus the importance of including surfactant stresses in SHS models. Our time-dependent protocol can assess the impact of surfactants in SHS testing and guide future mitigating designs.

A theory for the slip and drag of superhydrophobic surfaces with surfactant.

Superhydrophobic surfaces (SHSs) have the potential to reduce drag at solid boundaries. However, multiple independent studies have recently shown that small amounts of surfactant, naturally present in the environment, can induce Marangoni forces that increase drag, at least in the laminar regime. To obtain accurate drag predictions, one must solve the mass, momentum, bulk surfactant and interfacial surfactant conservation equations. This requires expensive simulations, thus preventing surfactant from being widely considered in SHS studies. To address this issue, we propose a theory for steady, pressure-driven, laminar, two-dimensional flow in a periodic SHS channel with soluble surfactant. We linearise the coupling between flow and surfactant, under the assumption of small concentration, finding a scaling prediction for the local slip length. To obtain the drag reduction and interfacial shear, we find a series solution for the velocity field by assuming Stokes flow in the bulk and uniform interfacial shear. We find how the slip and drag depend on the nine dimensionless groups that together characterize the surfactant transport near SHSs, the gas fraction and the normalized interface length. Our model agrees with numerical simulations spanning orders of magnitude in each dimensionless group. The simulations also provide the constants in the scaling theory. Our model significantly improves predictions relative to a surfactant-free one, which can otherwise overestimate slip and underestimate drag by several orders of magnitude. Our slip length model can provide the boundary condition in other simulations, thereby accounting for surfactant effects without having to solve the full problem.