Defect-Density-Controlled Phase-Change Phenomena.

Juxtaposing hydrophilicity and hydrophobicity on the same surface, known as hybrid surface engineering, can enhance phase-change heat transfer. However, controlling hydrophilicity on hybrid surfaces in a scalable fashion is a challenge, limiting their application. Here, using widely available metal meshes with variable dimensions and by controlling the patterning pressure, we scalably fabricate hybrid surfaces having spot and gridlike patterns using stamping. Using fog harvesting in a controlled chamber, we show that optimized hybrid surfaces have a ∼37% higher fog harvesting rate when compared to homogeneous superhydrophobic surfaces. Furthermore, condensation frosting experiments reveal that, on grid-patterned hybrid surfaces, frost propagates at ∼160% higher velocity and provides ∼20% less frost coverage when compared to homogeneous superhydrophobic surfaces. During defrost, our hybrid surfaces retain more water when compared to superhydrophobic surfaces due to the presence of hydrophilic patterns and melt water pinning. We adapt our fabrication technique to roll-to-roll patterning, demonstrating wettability contrast on round metallic geometries via atmospheric water vapor condensation. This work provides guidelines for the rapid, substrate-independent, and scalable fabrication of hybrid wettability surfaces for a wide variety of applications.

Durability and Degradation Mechanisms of Antifrosting Surfaces.

Rapid implementation of renewable energy technologies has exacerbated the potential for economic loss and safety concerns caused by ice and frost accretion, which occurs on the surfaces of wind turbine blades, photovoltaic panels, and residential and electric vehicle air-source heat pumps. The past decade has seen advances in surface chemistry and micro- and nanostructures that can promote passive antifrosting and enhance defrosting. However, the durability of these surfaces remains the major obstacle preventing real-life applications, with degradation mechanisms remaining poorly understood. Here, we conducted durability tests on antifrosting surfaces, including superhydrophobic, hydrophobic, superhydrophilic, and slippery liquid-infused surfaces. For superhydrophobic surfaces, we demonstrate durability with progressive degradation for up to 1000 cycles of atmospheric frosting-defrosting and month-long outdoor exposure tests. We show that progressive degradation, as reflected by increased condensate retention and reduced droplet shedding, results from molecular-level degradation of the low-surface-energy self-assembled monolayer (SAM). The degradation of the SAM leads to local high-surface-energy defects, which further deteriorate the surface by promoting accumulation of atmospheric particulate matter during cyclic condensation, frosting, and melt drying. Furthermore, cyclic frosting and defrost tests demonstrate the durability and degradation mechanisms of other surfaces to show, for example, the loss of water affinity of superhydrophilic surfaces after 22 days due to atmospheric volatile organic compound (VOC) adsorption and significant lubricant drainage for lubricant-infused surfaces after 100 cycles. Our work reveals the degradation mechanism of functional surfaces during exposure to long-term frost-defrost cycling and elucidates guidelines for the development of future surfaces for real-life antifrosting/icing applications.

Life Span of Slippery Lubricant Infused Surfaces.

Since their discovery a decade ago, slippery liquid infused porous surfaces (SLIPSs) or lubricant infused surfaces (LISs) have been demonstrated time and again to have immense potential for a plethora of applications. Of these, one of the most promising is enhancing the energy efficiency of both thermoelectric and organic Rankine cycle power generation via enhanced vapor condensation. However, utilization of SLIPSs in the energy sector remains limited due to the poor understanding of their life span. Here, we use controlled conditions to conduct multimonth steam and ethanol condensation tests on ultrascalable nanostructured copper oxide structured surfaces impregnated with mineral and fluorinated lubricants having differing viscosities (9.7 mPa·s < µ < 5216 mPa·s) and chemical structures. Our study demonstrates that SLIPSs lose their hydrophobicity during steam condensation after 1 month due to condensate cloaking. However, these same SLIPSs maintain nonwetting after 5 months of ethanol condensation due to the absence of cloaking. Surfaces impregnated with higher viscosity oil (5216 mPa·s) increase the life span to more than 8 months of continuous ethanol condensation. Vapor shear tests revealed that SLIPSs do not undergo oil depletion during exposure to 10 m/s gas flows, critical to condenser implementation where single-phase superheated vapor impingement is prevalent. Furthermore, higher viscosity SLIPSs are shown to maintain good stability after exposure to 200 °C air. A subset of the durable SLIPSs did not show change in slipperiness after submerging in stagnant water and ethanol for up to 2 weeks, critical to condenser implementation where single-phase condensate immersion is prevalent. Our work not only demonstrates design methods and longevity statistics for slippery nanoengineered surfaces undergoing long-term dropwise condensation of steam and ethanol but also develops the fundamental design guidelines for creating durable slippery liquid infused surfaces.