Surface wettability has emerged as a powerful tool to influence phase change phenomena such as ice formation and steam condensation. Ice mitigation using passive coatings offers tremendous promise; however, there remain several fundamental, durability- and manufacturing-related challenges that need to be addressed to harness the benefits of these coatings. Challenges limiting industrial utilization of such coatings can be classified into three categories: fundamental (frost buildup, non-zero ice adhesion, bulk ice nucleation, variable icing conditions), durability-related (harsh environment resistance, liquid impact resistance, erosion, fatigue), and manufacturing-related (scalability, coating economics). The role of passive surfaces in enhancing condensation heat transfer is a potential game changer in power plant efficiency enhancement; however, the benefits of such coatings will only be realized when durability and manufacturing challenges have been fully addressed.

Droplet impact dynamics determines the performance of surfaces used in many applications such as anti-icing, condensation, boiling, and heat transfer. We study impact dynamics of water droplets on surfaces with chemistry/texture ranging from hydrophilic to superhydrophobic and across a temperature range spanning below freezing to near boiling conditions. Droplet retraction shows very strong temperature dependence especially on hydrophilic surfaces; it is seen that lower substrate temperatures lead to lesser retraction. Physics-based analyses show that the increased viscosity associated with lower temperatures combined with an increased work of adhesion can explain the decreased retraction. The present findings serve as a starting point to guide further studies of dynamic fluid-surface interaction at various temperatures.

Prevention of ice accretion and adhesion on surfaces is relevant to many applications, leading to improved operation safety, increased energy efficiency, and cost reduction. Development of passive nonicing coatings is highly desirable, since current antiicing strategies are energy and cost intensive. Superhydrophobicity has been proposed as a lead passive nonicing strategy, yet the exact mechanism of delayed icing on these surfaces is not clearly understood. In this work, we present an in-depth analysis of ice formation dynamics upon water droplet impact on surfaces with different wettabilities. We experimentally demonstrate that ice nucleation under low-humidity conditions can be delayed through control of surface chemistry and texture. Combining infrared (IR) thermometry and high-speed photography, we observe that the reduction of water-surface contact area on superhydrophobic surfaces plays a dual role in delaying nucleation: first by reducing heat transfer and second by reducing the probability of heterogeneous nucleation at the water-substrate interface. This work also includes an analysis (based on classical nucleation theory) to estimate various homogeneous and heterogeneous nucleation rates in icing situations. The key finding is that ice nucleation delay on superhydrophobic surfaces is more prominent at moderate degrees of supercooling, while closer to the homogeneous nucleation temperature, bulk and air-water interface nucleation effects become equally important. The study presented here offers a comprehensive perspective on the efficacy of textured surfaces for nonicing applications.