Dropwise condensation (DWC) heat transfer depends strongly on the maximum diameter (Dmax) of condensate droplets departing from the condenser surface. This study presents a facile technique implemented to gain control of Dmax in DWC within vapor/air atmospheres. We demonstrate how this approach can enhance the corresponding heat transfer rate by harnessing the capillary forces in the removal of the condensate from the surface. We examine various hydrophilic-superhydrophilic patterns, which, respectively, sustain and combine DWC and filmwise condensation on the substrate. The material system uses laser-patterned masking and chemical etching to achieve the desired wettability contrast and does not employ any hydrophobizing agent. By applying alternating straight parallel strips of hydrophilic (contact angle ∼78°) mirror-finish aluminum and superhydrophilic regions (etched aluminum) on the condensing surface, we show that the average maximum droplet size on the less-wettable domains is nearly 42% of the width of the corresponding strips. An overall improvement in the condensate collection rate, up to 19% (as compared to the control case of DWC on mirror-finish aluminum) was achieved by using an interdigitated superhydrophilic track pattern (on the mirror-finish hydrophilic surface) inspired by the vein network of plant leaves. The bioinspired interdigitated pattern is found to outperform the straight hydrophilic-superhydrophilic pattern design, particularly under higher humidity conditions in the presence of noncondensable gases (NCG), a condition that is more challenging for maintaining sustained DWC.

It is not common practice to deposit thin films on metal substrates, especially copper, which is a common heat exchanger metal and practical engineering material known for its heat transfer properties. While single crystal substrates offer ideal surfaces with uniform structure for compatibility with oxide deposition, metallic surfaces needed for industrial applications exhibit non-idealities that complicate the fabrication of oxide nanostructure arrays. The following study explored different ZnO fabrication techniques to deposit a (super)hydrophobic thin film of ZnO on a metal substrate, specifically copper, in order to explore its feasibility as an enhanced condensing surface. ZnO was selected for its non-toxicity, ability to be made (super)hydrophobic with hierarchical roughness, and its photoinduced hydrophilicity characteristic, which could be utilized to pattern it to have both hydrophobic-hydrophilic regions. We investigated the variation of ZnO's morphology and wetting state, using SEMs and sessile drop contact angle measurements, as a function of different fabrication techniques: sputtering, pulsed laser deposition (PLD), electrodeposition and annealing Zn. We successfully fabricated (super)hydrophobic ZnO on a mirror finish, commercially available copper substrate using the scalable electrodeposition technique. PLD for ZnO deposition did not prove viable, as the ZnO samples on metal substrates were hydrophilic and the process does not lend itself to scalability. The annealed Zn sheets did not exhibit consistent wetting state results.

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Experimental studies of dropwise condensation have generally indicated that higher heat transfer coefficients correspond to smaller mean sizes for droplets growing through condensation on the surface. Recent investigations of dropwise condensation on nanostructured surfaces suggest that optimizing the design of such surfaces can push mean droplet sizes down to smaller values and significantly enhance heat transfer. This paper summarizes a theoretical exploration of the limits of heat transfer enhancement that can be achieved by pushing mean droplet size to progressively smaller sizes. A model analysis is developed that predicts transport near clusters of water droplets undergoing dropwise condensation. The model accounts for interfacial tension effects on thermodynamic equilibrium and noncontinuum transport effects, which become increasingly important as droplet size becomes progressively smaller. In this investigation, the variation of condensing heat transfer coefficient for droplet clusters of different size was explored for droplet diameters ranging from hundreds of microns to tens of nanometers. The model predictions indicate that the larger droplet transport trend of increasing heat transfer coefficient with decreasing mean droplet size breaks down as droplet size becomes smaller. The model further predicts that as drop size becomes smaller, a peak heat transfer coefficient is reached, beyond which the coefficient drops as the size continues to diminish. This maximum heat transfer coefficient results from the increasing importance of surface tension effects and non-continuum effects as droplet size becomes smaller. The impact of these predictions on the interpretation of dropwise condensation heat transfer data, and the implications for design of nanostructured surfaces to enhance dropwise condensation are discussed in detail.

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