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Durable One-Dimensional Liquid-Infused Surface for Practical Dropwise Condensation Enhancement.

Seyed Ahmadreza Kia1, Hossein Pakzad1, Behzad Rezaee1

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This study developed a durable, low-cost liquid-infused surface (LIS) on aluminum using UV light and silicone oils. The enhanced surface improves condensation efficiency and corrosion resistance, offering a scalable solution for various applications.

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Area of Science:

  • Materials Science
  • Surface Chemistry
  • Nanotechnology

Background:

  • Liquid-infused surfaces (LISs) show potential for condensation enhancement due to tunable surface properties like contact angle (CA) and contact angle hysteresis (CAH).
  • Existing LIS technologies face challenges including poor durability, high manufacturing costs, and scalability issues, limiting their practical implementation.
  • Developing robust and cost-effective LIS is crucial for advancing applications in heat transfer, anti-icing, and microfluidics.

Purpose of the Study:

  • To fabricate a durable, low-cost, one-dimensional LIS on aluminum using UV-initiated surface modification without hazardous materials.
  • To investigate the effect of UV exposure time and lubricant viscosity on the surface properties and performance of the LIS.
  • To evaluate the condensation enhancement, corrosion resistance, and durability of the fabricated LIS compared to bare aluminum and existing literature.

Main Methods:

  • Aluminum substrates were coated with silicone oils of varying viscosities and decamethylcyclopentasiloxane (D5).
  • Surfaces were exposed to ultraviolet (UV) light for short-term (10 h) and long-term (gelation time dependent) durations to create chemically bonded lubricant layers.
  • Contact angle (CA) and contact angle hysteresis (CAH) measurements were performed to characterize surface wettability.
  • Electrochemical corrosion tests were conducted to assess corrosion resistance.
  • Condensation tests were performed at various subcooling temperatures to quantify condensation enhancement.

Main Results:

  • All fabricated LIS exhibited chemically bonded lubricants with a high contact angle (>100°) and low contact angle hysteresis (<10°).
  • The LIS demonstrated a significant reduction in corrosion current density (up to two orders of magnitude) compared to bare aluminum.
  • A surface treated with 5 cSt silicone oil and 10 h UV exposure enhanced condensation by 29%–39% at different subcooling levels.
  • The durability of the fabricated LIS was improved by 350% compared to existing literature benchmarks.

Conclusions:

  • UV-initiated surface modification provides a scalable, cost-effective, and environmentally friendly method for creating durable LIS on aluminum.
  • The developed LIS exhibits excellent anti-corrosion properties and significantly enhances condensation efficiency.
  • This technology offers a promising solution for improving thermal management systems and other applications requiring efficient water droplet manipulation.