Synthetic Butterfly Scale Surfaces with Compliance-Tailored Anisotropic Drop Adhesion.

Many natural surfaces such as butterfly wings, beetles' backs, and rice leaves exhibit anisotropic liquid adhesion; this is of fundamental interest and is important to applications including self-cleaning surfaces, microfluidics, and phase change energy conversion. Researchers have sought to mimic the anisotropic adhesion of butterfly wings using rigid surface textures, though natural butterfly scales are sufficiently compliant to be deflected by capillary forces exerted by drops. Here, inspired by the flexible scales of the Morpho aega butterfly wing, synthetic surfaces coated with flexible carbon nanotube (CNT) microscales with anisotropic drop adhesion properties are fabricated. The curved CNT scales are fabricated by a strain-engineered chemical vapor deposition technique, giving ≈5000 scales of ≈10 µm thickness in a 1 cm2 area. Using various designed CNT scale arrays, it is demonstrated that the anisotropy of drop roll-off angle is influenced by the geometry, compliance, and hydrophobicity of the scales; and a maximum roll-off anisotropy of 6.2° is achieved. These findings are supported by a model that relates the adhesion anisotropy to the scale geometry, compliance, and wettability. The electrical conductivity and mechanical robustness of the CNTs, and the ability to fabricate complex multidirectional patterns, suggest further opportunities to create engineered synthetic scale surfaces.

Dropwise condensation of low surface tension fluids on omniphobic surfaces.

Compared to the significant body of work devoted to surface engineering for promoting dropwise condensation heat transfer of steam, much less attention has been dedicated to fluids with lower interfacial tension. A vast array of low-surface tension fluids such as hydrocarbons, cryogens, and fluorinated refrigerants are used in a number of industrial applications, and the development of passive means for increasing their condensation heat transfer coefficients has potential for significant efficiency enhancements. Here we investigate condensation behavior of a variety of liquids with surface tensions in the range of 12 to 28 mN/m on three types of omniphobic surfaces: smooth oleophobic, re-entrant superomniphobic, and lubricant-impregnated surfaces. We demonstrate that although smooth oleophobic and lubricant-impregnated surfaces can promote dropwise condensation of the majority of these fluids, re-entrant omniphobic surfaces became flooded and reverted to filmwise condensation. We also demonstrate that on the lubricant-impregnated surfaces, the choice of lubricant and underlying surface texture play a crucial role in stabilizing the lubricant and reducing pinning of the condensate. With properly engineered surfaces to promote dropwise condensation of low-surface tension fluids, we demonstrate a four to eight-fold improvement in the heat transfer coefficient.

Stable dropwise condensation for enhancing heat transfer via the initiated chemical vapor deposition (iCVD) of grafted polymer films.

Ultra-thin copolymer films are deposited by initiated chemical deposition (iCVD) to investigate their performance under the condensation of water vapor. By forming a grafted interface between the coating and the substrate, the films exhibit stable dropwise condensation even when subjected to 100 °C steam. The applicability of the iCVD to complex substrate geometries is demonstrated on a copper condenser coil.

Self-similarity of contact line depinning from textured surfaces.

The mobility of drops on surfaces is important in many biological and industrial processes, but the phenomena governing their adhesion, which is dictated by the morphology of the three-phase contact line, remain unclear. Here we describe a technique for measuring the dynamic behaviour of the three-phase contact line at micron length scales using environmental scanning electron microscopy. We examine a superhydrophobic surface on which a drop's adhesion is governed by capillary bridges at the receding contact line. We measure the microscale receding contact angle of each bridge and show that the Gibbs criterion is satisfied at the microscale. We reveal a hitherto unknown self-similar depinning mechanism that shows how some hierarchical textures such as lotus leaves lead to reduced pinning, and counter-intuitively, how some lead to increased pinning. We develop a model to predict adhesion force and experimentally verify the model's broad applicability on both synthetic and natural textured surfaces.

Hydrophobicity of rare-earth oxide ceramics.

Hydrophobic materials that are robust to harsh environments are needed in a broad range of applications. Although durable materials such as metals and ceramics, which are generally hydrophilic, can be rendered hydrophobic by polymeric modifiers, these deteriorate in harsh environments. Here we show that a class of ceramics comprising the entire lanthanide oxide series, ranging from ceria to lutecia, is intrinsically hydrophobic. We attribute their hydrophobicity to their unique electronic structure, which inhibits hydrogen bonding with interfacial water molecules. We also show with surface-energy measurements that polar interactions are minimized at these surfaces and with Fourier transform infrared/grazing-angle attenuated total reflection that interfacial water molecules are oriented in the hydrophobic hydration structure. Moreover, we demonstrate that these ceramic materials promote dropwise condensation, repel impinging water droplets, and sustain hydrophobicity even after exposure to harsh environments. Rare-earth oxide ceramics should find widespread applicability as robust hydrophobic surfaces.

Multimode multidrop serial coalescence effects during condensation on hierarchical superhydrophobic surfaces.

The prospect of enhancing the condensation rate by decreasing the maximum drop departure diameter significantly below the capillary length through spontaneous drop motion has generated significant interest in condensation on superhydrophobic surfaces (SHS). The mobile coalescence leading to spontaneous drop motion was initially reported to occur only on hierarchical SHS, consisting of both nanoscale and microscale topological features. However, subsequent studies have shown that mobile coalescence also occurs on solely nanostructured SHS. Thus, recent focus has been on understanding the condensation process on nanostructured surfaces rather than on hierarchical SHS. In this work, we investigate the impact of microscale topography of hierarchical SHS on the droplet coalescence dynamics and wetting states during the condensation process. We show that isolated mobile and immobile coalescence between two drops, almost exclusively focused on in previous studies, are rare. We identify several new droplet shedding modes, which are aided by tangential propulsion of mobile drops. These droplet shedding modes comprise of multiple droplets merging during serial coalescence events, which culminate in formation of a drop that either departs or remains anchored to the surface. We directly relate postmerging drop adhesion to formation of drops in nanoscale as well as microscale Wenzel and Cassie-Baxter wetting states. We identify the optimal microscale feature spacing of the hierarchical SHS, which promotes departure of the highest number of microdroplets. This optimal surface architecture consists of microscale features spaced close enough to enable transition of larger droplets into micro-Cassie state yet, at the same time, provides sufficient spacing in-between the features for occurrence of mobile coalescence.

Enhanced condensation on lubricant-impregnated nanotextured surfaces.

Nanotextured superhydrophobic surfaces have received significant attention due to their ability to easily shed liquid drops. However, water droplets have been shown to condense within the textures of superhydrophobic surfaces, impale the vapor pockets, and strongly pin to the surface. This results in poor droplet mobility and degrades condensation performance. In this paper, we show that pinning of condensate droplets can be drastically reduced by designing a hierarchical micro-nanoscale texture on a surface and impregnating it with an appropriate lubricant. The choice of lubricant must take into account the surface energies of all phases present. A lubricant will cloak the condensate and inhibit growth if the spreading coefficient is positive. If the lubricant does not fully wet the solid, we show how condensate-solid pinning can be reduced by proper implementation of nanotexture. On such a surface, condensate droplets as small as 100 µm become highly mobile and move continuously at speeds that are several orders of magnitude higher than those on identically textured superhydrophobic surfaces. This remarkable mobility produces a continuous sweeping effect that clears the surface for fresh nucleation and results in enhanced condensation.

Rapid deceleration-driven wetting transition during pendant drop deposition on superhydrophobic surfaces.

A hitherto unknown mechanism for wetting transition is reported. When a pendant drop settles upon deposition, there is a virtual "collision" where its center of gravity undergoes rapid deceleration. This induces a high water hammer-type pressure that causes wetting transition. A new phase diagram shows that both large and small droplets can transition to wetted states due to the new deceleration driven and the previously known Laplace mechanisms, respectively. It is explained how the attainment of a nonwetted Cassie-Baxter state is more restrictive than previously known.