Metal Surface Engineering for Extreme Sustenance of Jumping Droplet Condensation.

Water vapor condensation on metallic surfaces is critical to a broad range of applications, ranging from power generation to the chemical and pharmaceutical industries. Enhancing simultaneously the heat transfer efficiency, scalability, and durability of a condenser surface remains a persistent challenge. Coalescence-induced condensing droplet jumping is a capillarity-driven mechanism of self-ejection of microscopic condensate droplets from a surface. This mechanism is highly desired due to the fact that it continuously frees up the surface for new condensate to form directly on the surface, enhancing heat transfer without requiring the presence of the gravitational field. However, this condensate ejection mechanism typically requires the fabrication of surface nanotextures coated by an ultrathin (<10 nm) conformal hydrophobic coating (hydrophobic self-assembled monolayers such as silanes), which results in poor durability. Here, we present a scalable approach for the fabrication of a hierarchically structured superhydrophobic surface on aluminum substrates, which is able to withstand adverse conditions characterized by condensation of superheated steam shear flow at pressure and temperature up to ≈1.42 bar and ≈111 °C, respectively, and velocities in the range ≈3-9 m/s. The synergetic function of micro- and nanotextures, combined with a chemically grafted, robust ultrathin (≈4.0 nm) poly-1H,1H,2H,2H-perfluorodecyl acrylate (pPFDA) coating, which is 1 order of magnitude thinner than the current state of the art, allows the sustenance of long-term coalescence-induced condensate jumping drop condensation for at least 72 h. This yields unprecedented, up to an order of magnitude higher heat transfer coefficients compared to filmwise condensation under the same conditions and significantly outperforms the current state of the art in terms of both durability and performance establishing a new milestone.

4D Force Detection of Cell Adhesion and Contractility.

Mechanical signals establish two-way communication between mammalian cells and their environment. Cells contacting a surface exert forces via contractility and transmit them at the areas of focal adhesions. External stimuli, such as compressive and pulling forces, typically affect the adhesion-free cell surface. Here, we demonstrate the collaborative employment of Fluidic Force Microscopy and confocal Traction Force Microscopy supported by the Cellogram solver to enable a powerful integrated force probing approach, where controlled vertical forces are applied to the free surface of individual cells, while the concomitant deformations are used to map their transmission to the substrate. Force transmission across human cells is measured with unprecedented temporal and spatial resolution, enabling the investigation of the cellular mechanisms involved in the adaptation, or maladaptation, to external mechanical stimuli. Altogether, the system enables facile and precise force interrogation of individual cells, with the capacity to perform population-based analysis.

Out-of-Plane Biphilic Surface Structuring for Enhanced Capillary-Driven Dropwise Condensation.

Rapid and sustained condensate droplet departure from a surface is key toward achieving high heat-transfer rates in condensation, a physical process critical to a broad range of industrial and societal applications. Despite the progress in enhancing condensation heat transfer through inducing its dropwise mode with hydrophobic materials, sophisticated surface engineering methods that can lead to further enhancement of heat transfer are still highly desirable. Here, by employing a three-dimensional, multiphase computational approach, we present an effective out-of-plane biphilic surface topography, which reveals an unexplored capillarity-driven departure mechanism of condensate droplets. This texture consists of biphilic diverging microcavities wherein a matrix of small hydrophilic spots is placed at their bottom, that is, among the pyramid-shaped, superhydrophobic microtextures forming the cavities. We show that an optimal combination of the hydrophilic spots and the angles of the pyramidal structures can achieve high deformational stretching of the droplets, eventually realizing an impressive "slingshot-like" droplet ejection process from the texture. Such a droplet departure mechanism has the potential to reduce the droplet ejection volume and thus enhance the overall condensation efficiency, compared to coalescence-initiated droplet jumping from other state-of-the-art surfaces. Simulations have shown that optimal pyramid-shaped biphilic microstructures can provoke droplet self-ejection at low volumes, up to 56% lower than superhydrophobic straight pillars, revealing a promising new surface microtexture design strategy toward enhancing the condensation heat-transfer efficiency and water harvesting capabilities.

Superhydrophobic surfaces for extreme environmental conditions.

Superhydrophobic surfaces for repelling impacting water droplets are typically created by designing structures with capillary (antiwetting) pressures greater than those of the incoming droplet (dynamic, water hammer). Recent work has focused on the evolution of the intervening air layer between droplet and substrate during impact, a balance of air compression and drainage within the surface texture, and its role in affecting impalement under ambient conditions through local changes in the droplet curvature. However, little consideration has been given to the influence of the intervening air-layer thermodynamic state and composition, in particular when departing from standard atmospheric conditions, on the antiwetting behavior of superhydrophobic surfaces. Here, we explore the related physics and determine the working envelope for maintaining robust superhydrophobicity, in terms of the ambient pressure and water vapor content. With single-tier and multitier superhydrophobic surfaces and high-resolution dynamic imaging of the droplet meniscus and its penetration behavior into the surface texture, we expose a trend of increasing impalement severity with decreasing ambient pressure and elucidate a previously unexplored condensation-based impalement mechanism within the texture resulting from the compression, and subsequent supersaturation, of the intervening gas layer in low-pressure, humid conditions. Using fluid dynamical considerations and nucleation thermodynamics, we provide mechanistic understanding of impalement and further employ this knowledge to rationally construct multitier surfaces with robust superhydrophobicity, extending water repellency behavior well beyond typical atmospheric conditions. Such a property is expected to find multifaceted use exemplified by transportation and infrastructure applications where exceptional repellency to water and ice is desired.

Ultrathin Durable Organic Hydrophobic Coatings Enhancing Dropwise Condensation Heat Transfer.

Organic hydrophobic layers targeting sustained dropwise condensation are highly desirable but suffer from poor chemical and mechanical stability, combined with low thermal conductivity. The requirement of such layers to remain ultrathin to minimize their inherent thermal resistance competes against durability considerations. Here, we investigate the long-term durability and enhanced heat-transfer performance of perfluorodecanethiol (PFDT) coatings compared to alternative organic coatings, namely, perfluorodecyltriethoxysilane (PFDTS) and perfluorodecyl acrylate (PFDA), the latter fabricated with initiated chemical vapor deposition (iCVD), in condensation heat transfer and under the challenging operating conditions of intense flow (up to 9 m s-1) of superheated steam (111 °C) at high pressures (1.42 bar). We find that the thiol coating clearly outperforms the silane coating in terms of both heat transfer and durability. In addition, despite being only a monolayer, it clearly also outperforms the iCVD-fabricated PFDA coating in terms of durability. Remarkably, the thiol layer exhibited dropwise condensation for at least 63 h (>2× times more than the PFDA coating, which survived for 30 h), without any visible deterioration, showcasing its hydrolytic stability. The cost of thiol functionalization per area was also the lowest as compared to all of the other surface hydrophobic treatments used in this study, thus making it the most efficient option for practical applications on copper substrates.

Mechanical Fingerprint of Senescence in Endothelial Cells.

Endothelial senescence entails alterations of the healthy cell phenotype, which accumulate over time and contribute to cardiovascular disease. Mechanical aspects regulating cell adhesion, force generation, and the response to flow contribute to the senescence-associated drift; however, they remain largely unexplored. Here, we exploit force microscopy to resolve variations of the cell anchoring to the substrate and the tractions generated upon aging in the nanonewton (nN) range. Senescent endothelial cells display a multifold increase in the levels of basal adhesion and force generation supported by mature and strong focal adhesions. The enhanced mechanical interaction with the substrate yields static endothelial monolayers that polarize in response to flow but fail the process of coordinated cell shape remodeling and reorientation. The emerging picture indicates that senescence reinforces the local cell interaction with the substrate and may therefore prevent endothelial denudation; however, it compromises the ability to functionally adapt to the local hemodynamic conditions.

Spontaneous droplet trampolining on rigid superhydrophobic surfaces.

Spontaneous removal of condensed matter from surfaces is exploited in nature and in a broad range of technologies to achieve self-cleaning, anti-icing and condensation control. But despite much progress, our understanding of the phenomena leading to such behaviour remains incomplete, which makes it challenging to rationally design surfaces that benefit from its manifestation. Here we show that water droplets resting on superhydrophobic textured surfaces in a low-pressure environment can self-remove through sudden spontaneous levitation and subsequent trampoline-like bouncing behaviour, in which sequential collisions with the surface accelerate the droplets. These collisions have restitution coefficients (ratios of relative speeds after and before collision) greater than unity despite complete rigidity of the surface, and thus seemingly violate the second law of thermodynamics. However, these restitution coefficients result from an overpressure beneath the droplet produced by fast droplet vaporization while substrate adhesion and surface texture restrict vapour flow. We also show that the high vaporization rates experienced by the droplets and the associated cooling can result in freezing from a supercooled state that triggers a sudden increase in vaporization, which in turn boosts the levitation process. This effect can spontaneously remove surface icing by lifting away icy drops the moment they freeze. Although these observations are relevant only to systems in a low-pressure environment, they show how surface texturing can produce droplet-surface interactions that prohibit liquid and freezing water-droplet retention on surfaces.

Metals by Micro-Scale Additive Manufacturing: Comparison of Microstructure and Mechanical Properties.

Many emerging applications in microscale engineering rely on the fabrication of 3D architectures in inorganic materials. Small-scale additive manufacturing (AM) aspires to provide flexible and facile access to these geometries. Yet, the synthesis of device-grade inorganic materials is still a key challenge toward the implementation of AM in microfabrication. Here, a comprehensive overview of the microstructural and mechanical properties of metals fabricated by most state-of-the-art AM methods that offer a spatial resolution ≤10 µm is presented. Standardized sets of samples are studied by cross-sectional electron microscopy, nanoindentation, and microcompression. It is shown that current microscale AM techniques synthesize metals with a wide range of microstructures and elastic and plastic properties, including materials of dense and crystalline microstructure with excellent mechanical properties that compare well to those of thin-film nanocrystalline materials. The large variation in materials' performance can be related to the individual microstructure, which in turn is coupled to the various physico-chemical principles exploited by the different printing methods. The study provides practical guidelines for users of small-scale additive methods and establishes a baseline for the future optimization of the properties of printed metallic objects-a significant step toward the potential establishment of AM techniques in microfabrication.

Spontaneous self-dislodging of freezing water droplets and the role of wettability.

Spontaneous removal of liquid, solidifying liquid and solid forms of matter from surfaces, is of significant importance in nature and technology, where it finds applications ranging from self-cleaning to icephobicity and to condensation systems. However, it is a great challenge to understand fundamentally the complex interaction of rapidly solidifying, typically supercooled, droplets with surfaces, and to harvest benefit from it for the design of intrinsically icephobic materials. Here we report and explain an ice removal mechanism that manifests itself simultaneously with freezing, driving gradual self-dislodging of droplets cooled via evaporation and sublimation (low environmental pressure) or convection (atmospheric pressure) from substrates. The key to successful self-dislodging is that the freezing at the droplet free surface and the droplet contact area with the substrate do not occur simultaneously: The frozen phase boundary moves inward from the droplet free surface toward the droplet-substrate interface, which remains liquid throughout most of the process and freezes last. We observe experimentally, and validate theoretically, that the inward motion of the phase boundary near the substrate drives a gradual reduction in droplet-substrate contact. Concurrently, the droplet lifts from the substrate due to its incompressibility, density differences, and the asymmetric freezing dynamics with inward solidification causing not fully frozen mass to be displaced toward the unsolidified droplet-substrate interface. Depending on surface topography and wetting conditions, we find that this can lead to full dislodging of the ice droplet from a variety of engineered substrates, rendering the latter ice-free.

Transparent Metasurfaces Counteracting Fogging by Harnessing Sunlight.

Surface fogging is a common phenomenon that can have significant and detrimental effects on surface transparency and visibility. It affects the performance in a wide range of applications including windows, windshields, electronic displays, cameras, mirrors, and eyewear. A host of ongoing research is aimed at combating this problem by understanding and developing stable and effective antifogging coatings that are capable of handling a wide range of environmental challenges "passively" without consumption of electrical energy. Here we introduce an alternative approach employing sunlight to go beyond state-of-the-art techniques, such as superhydrophilic and superhydrophobic coatings, by rationally engineering solar absorbing metasurfaces that maintain transparency, while upon illumination induce localized heating to significantly delay the onset of surface fogging or decrease defogging time. For the same environmental conditions, we demonstrate that our metasurfaces are able to reduce defogging time by up to 4-fold and under supersaturated conditions inhibit the nucleation of condensate outperforming conventional state-of-the-art approaches in terms of visibility retention. Our research illustrates a durable and environmentally sustainable approach to passive antifogging and defogging for transparent surfaces. This work opens up the opportunity for large-scale manufacturing that can be applied to a range of materials, including polymers and other flexible substrates.

Cellogram: On-the-Fly Traction Force Microscopy.

Traction force microscopy (TFM) derives maps of cell-generated forces, typically in the nanonewton range, transmitted to the extracellular environment upon actuation of complex biological processes. In traditional approaches, force rendering requires a terminal, time-consuming step of cell deadhesion to obtain a reference image. A conceptually opposite approach is provided by reference-free methods, opening to the on-the-fly generation of force maps from an ongoing experiment. This requires an image processing algorithm keeping the pace of the biological phenomena under investigation. Here, we introduce an integrated software pipeline rendering force maps from single reference-free TFM images seconds to minutes after their acquisition. The algorithm tackles image processing, reference image estimation, and finite element analysis as a single problem, yielding a robust and fully automatic solution. The method's capabilities are demonstrated in two applications. First, the mechanical annihilation of cancer cells is monitored as a function of rising environmental temperature, setting a population threshold at 45 °C. Second, the fast temporal correlation of forces produced across individual cells is used to map physically connected adhesion points, yielding typical lengths that vary as a function of the cell cycle phase.

Superhydrophobicity enhancement through substrate flexibility.

Inspired by manifestations in nature, microengineering and nanoengineering of synthetic materials to achieve superhydrophobicity has been the focus of much work. Generally, hydrophobicity is enhanced through the combined effects of surface texturing and chemistry; being durable, rigid materials are the norm. However, many natural and technical surfaces are flexible, and the resulting effect on hydrophobicity has been largely ignored. Here, we show that the rational tuning of flexibility can work synergistically with the surface microtexture or nanotexture to enhance liquid repellency performance, characterized by impalement and breakup resistance, contact time reduction, and restitution coefficient increase. Reduction in substrate areal density and stiffness imparts immediate acceleration and intrinsic responsiveness to impacting droplets (∼350 × g), mitigating the collision and lowering the impalement probability by ∼60% without the need for active actuation. Furthermore, we exemplify the above discoveries with materials ranging from man-made (thin steel or polymer sheets) to nature-made (butterfly wings).

Pore Shape Defines Paths of Metastatic Cell Migration.

Invasion of dense tissues by cancer cells involves the interplay between the penetration resistance offered by interstitial pores and the deformability of cells. Metastatic cancer cells find optimal paths of minimal resistance through an adaptive path-finding process, which leads to successful dissemination. The physical limit of nuclear deformation is related to the minimal cross section of pores that can be successfully penetrated. However, this single biophysical parameter does not fully describe the architectural complexity of tissues featuring pores of variable area and shape. Here, employing laser nanolithography, we fabricate pore microenvironment models with well-controlled pore shapes, through which human breast cells (MCF10A) and their metastatic offspring (MCF10CA1a.cl1) could pervade. In these experimental settings, we demonstrate that the actual pore shape, and not only the cross section, is a major and independent determinant of cancer penetration efficiency. In complex architectures containing pores demanding large deformations from invading cells, tall and narrow rectangular openings facilitate cancer migration. In addition, we highlight the characteristic traits of the explorative behavior enabling metastatic cells to identify and select such pore shapes in a complex multishape pore environment, pinpointing paths of least resistance to invasion.

Endocytic reawakening of motility in jammed epithelia.

Dynamics of epithelial monolayers has recently been interpreted in terms of a jamming or rigidity transition. How cells control such phase transitions is, however, unknown. Here we show that RAB5A, a key endocytic protein, is sufficient to induce large-scale, coordinated motility over tens of cells, and ballistic motion in otherwise kinetically arrested monolayers. This is linked to increased traction forces and to the extension of cell protrusions, which align with local velocity. Molecularly, impairing endocytosis, macropinocytosis or increasing fluid efflux abrogates RAB5A-induced collective motility. A simple model based on mechanical junctional tension and an active cell reorientation mechanism for the velocity of self-propelled cells identifies regimes of monolayer dynamics that explain endocytic reawakening of locomotion in terms of a combination of large-scale directed migration and local unjamming. These changes in multicellular dynamics enable collectives to migrate under physical constraints and may be exploited by tumours for interstitial dissemination.

Two-Dimensional Drexhage Experiment for Electric- and Magnetic-Dipole Sources on Plasmonic Interfaces.

Fifty years ago, Drexhage et al. showed how photon emission from an electric dipole can be modified by a nearby mirror. Here, we study the two-dimensional analog for surface plasmon polaritons (SPPs). We print Eu^{3+}-doped nanoparticles, which act as both electric- and magnetic-dipole sources of SPPs, near plasmonic reflectors on flat Ag films. We measure modified SPP radiation patterns and emission rates as a function of reflector distance and source symmetry. The results, which agree with an analytical self-interference model, provide simple strategies to control SPP radiation in plasmonic devices.

Length Scale of Diffusive Phonon Transport in Suspended Thin Silicon Nanowires.

Recent experimental advances have revealed that the mean free path (mfp) of phonons contributing significantly to thermal transport in crystalline semiconductors can be several microns long. Almost all of these experiments are based on bulk and thin film materials and use techniques that are not directly applicable to nanowires. By developing a process with which we could fabricate multiple electrically contacted and suspended segments on individual heavily doped smooth Silicon nanowires, we measured phonon transport across varying length scales using a DC self-heating technique. Our measurements show that diffusive thermal transport is still valid across O(100) nm length scales, supporting the diffuse nature of phonon-boundary scattering even on smooth nanowire surfaces. Our work also showcases the self-heating technique as an important alternative to the thermal bridge technique to measure phonon transport across short length scales relevant to mapping the phonon mfp spectrum in nanowires.

Imparting Icephobicity with Substrate Flexibility.

Ice accumulation hinders the performance of, and poses safety threats for, infrastructure both on the ground and in the air. Previously, rationally designed superhydrophobic surfaces have demonstrated some potential as a passive means to mitigate ice accretion; however, further studies on material solutions that reduce impalement and the contact time for impacting supercooled droplets (high viscosity) and can also repel droplets that freeze during surface contact are urgently needed. Here we demonstrate the collaborative effect of substrate flexibility and surface micro/nanotexture on enhancing both icephobicity and the repellency of viscous droplets (typical of supercooled water). We first investigate the influence of increased viscosity (spanning from 0.9 to 1078 mPa·s using water-glycerol mixtures) on impalement resistance and the droplet-substrate contact time after impact. Then we examine the effect of droplet partial solidification on recoil and simulate more challenging icing conditions by impacting supercooled water droplets (down to -15 °C) onto flexible and rigid surfaces containing ice nucleation promoters (AgI). We demonstrate a passive mechanism for shedding partially solidified (recalescent) droplets-under conditions where partial solidification occurs much faster than the natural droplet oscillation-which does not rely on converting droplet surface energy into kinetic energy (classic recoil mechanism). Using an energy-based model (kinetic-elastic-capillary), we identify a previously unexplored mechanism whereby the substrate oscillation and velocity govern the rebound process, with low areal density and moderately stiff substrates acting to efficiently absorb the incoming droplet kinetic energy and rectify it back, allowing droplets to overcome adhesion and gravitational forces, and recoil. This mechanism applies for a range of droplet viscosities, spanning from low- to high-viscosity fluids and even ice slurries, which do not rebound from rigid superhydrophobic substrates. For a low-viscosity fluid, i.e., water, if the substrate oscillates faster than the droplet spreading and retraction, the action of the substrate is decoupled from the droplet oscillation, resulting in a reduction in the droplet-substrate contact time.

Contactless Transport and Mixing of Liquids on Self-Sustained Sublimating Coatings.

Controlled handling of liquids and colloidal suspensions as they interact with surfaces, targeting a broad palette of related functionalities, is of great importance in science, technology, and nature. When small liquid volumes (drops on the order of microliters or nanoliters) need to be processed in microfluidic devices, contamination on the solid/liquid interface and loss of liquid due to adhesion on the transport channels are two very common problems that can significantly alter the process outcome, for example, the chemical reaction efficiency or the purity and the final concentration of a suspension. It is, therefore, no surprise that both levitation and minimal contact transport methods-including nonwetting surfaces-have been developed to minimize the interactions between liquids and surfaces. Here, we demonstrate contactless surface levitation and transport of liquid drops, realized by harnessing and sustaining the natural sublimation of a solid-carbon-dioxide-coated substrate to generate a continuous supporting vapor layer. The capability and limitations of this technique in handling liquids of extreme surface tension and kinematic viscosity values are investigated both experimentally and theoretically. The sublimating coating is capable of repelling many viscous and low-surface-tension liquids, colloidal suspensions, and non-Newtonian fluids as well, displaying outstanding omniphobic properties. Finally, we demonstrate how sublimation can be used for liquid transport, mixing, and drop coalescence, with a sublimating layer coated on an underlying substrate with prefabricated channels, conferring omniphobicity using a simple physical approach (i.e., phase change) rather than a chemical one. The independence of the surface levitation principle from material properties, such as electromagnetic, thermal or optical, surface energy, adhesion, or mechanical properties, renders this method attractive for a wide range of potential applications.

Detergency and Its Implications for Oil Emulsion Sieving and Separation.

Separating petroleum hydrocarbons from water is an important problem to address in order to mitigate the disastrous effects of hydrocarbons on aquatic ecosystems. A rational approach to address the problem of marine oil-water separation is to disperse the oil with the aid of surfactants in order to minimize the formation of large slicks at the water surface and to maximize the oil-water interfacial area. Here we investigate the fundamental wetting and transport behavior of such surfactant-stabilized droplets and the flow conditions necessary to perform sieving and separation of these stabilized emulsions. We show that, for water-soluble surfactants, such droplets are completely repelled by a range of materials (intrinsically underwater superoleophobic) due to the detergency effect; therefore, there is no need for surface micro-/nanotexturing or chemical treatment to repel the oil and prevent fouling of the filter. We then simulate and experimentally investigate the effect of emulsion flow rate on the transport and impact behavior of such droplets on rigid meshes to identify the minimum pore opening (w) necessary to filter a droplet with a given diameter (d) in order to minimize the pressure drop across the mesh-and therefore maximize the filtering efficiency, which is strongly dependent on w. We define a range of flow conditions and droplet sizes where minimum droplet deformation is to be expected and therefore find that the condition of w ≈ d is sufficient for efficient separation. With this new understanding, we demonstrate the use of a commercially available filter-without any additional surface engineering or functionalization-to separate oil droplets (d < 100 µm) from a surfactant-stabilized emulsion with a flux of ∼11,000 L m-2 h-1 bar-1. We believe these findings can inform the design of future oil separation materials.

Surface Chemical Tuning of Phonon and Electron Transport in Free-Standing Silicon Nanowire Arrays.

We report electronic and phononic transport measurements of monocrystalline batch-fabricated silicon nanowire (SiNW) arrays functionalized with different surface chemistries. We find that hydrogen-terminated SiNWs prepared by vapor HF etching of native-oxide-covered devices show increased electrical conductivity but decreased thermal conductivity. We used the kinetic Monte Carlo method to solve the Boltzmann transport equation and also numerically examine the effect of phonon boundary scattering. Surface transfer doping of the SiNWs by cobaltocene or decamethylcobaltocene drastically improves the electrical conductivity by 2 to 4 orders of magnitude without affecting the thermal conductivity. The results showcase surface chemical control of nanomaterials as a potent pathway that can complement device miniaturization efforts in the quest for more efficient thermoelectric materials and devices.