Riblets inspired by shark skin exhibit a great air drag reduction potential in many industries, such as the aircraft, energy, and transportation industries. Many studies have reported that blade riblets attain the highest air drag reduction ability, with a current limit of ∼11%.Here, we propose multilayer hierarchical riblets (MLHRs) to further improve the air drag reduction ability. MLHRs were fabricated via a three-layer hybrid mask lithography method, and the air drag reduction ability was studied in a closed air channel. The experimental results indicated that the maximum air drag reduction achieved with MLHRs in the closed channel was 16.67%, which represents a 52% higher reduction than the highest previously reported. Conceptual models were proposed to explain the experiments from a microscopic perspective. MLHRs enhanced the stability of lifting and pinning vortices, while vortices gradually decelerated further, reducing the momentum exchange occurring near the wall. This verified that MLHRs overcome the current air drag reduction limit of riblets. The conceptual models lay a foundation to further improve the air drag reduction ability of riblets.

Drag reduction is a significant challenge for many industries, such as ships, pipelines, aircraft, energy, and transportation. Multilayer hierarchical microstructures can inhibit the development of vortices near the wall, which is beneficial to drag reduction. However, existing methods have difficulty performing the controlled fabrication of complex multilayer hierarchical microstructure arrays. Here, a novel triple lithography method based on three-layer hybrid masks is proposed for the controlled fabrication of three-dimensional multilayer hierarchical microstructure surfaces. The capability of the proposed process is verified by the multilayer hierarchical microstructures. In the fabrication process, a special lithography sequence is designed based on the hybrid mask materials. The drag reduction ability of the multilayer hierarchical microstructures is investigated in a closed air channel measurement system. The experimental results demonstrate that the fabricated multilayer hierarchical microstructures exhibit significant drag reduction ability under certain conditions. Conceptual models based on the fluid-solid coupling interface interaction are proposed to explain the drag reduction mechanism of multilayer hierarchical microstructures. The proposed fabrication method provides a powerful means for practical engineering applications of various bioinspired functional surfaces, such as drag reduction, anti-icing, antifouling, self-cleaning, and superhydrophobic surfaces.

Biomimetic riblet surfaces, such as blade, wavy, sinusoidal, and herringbone riblet surfaces, have widespread applications for drag reduction in the energy, transportation, and biomedicine industries. The drag reduction ability of a blade riblet surface is sensitive to the yaw angle, which is the angle between the design direction of the riblet surface and the average flow direction. In practical applications, the average flow direction is often misaligned with the design direction of riblet surfaces with different morphologies and arrangements. However, previous studies have not reported on the drag reduction characteristics and regularities related to the yaw angle for surfaces with complex riblet microstructures. For the first time, we systematically investigated the aerodynamic drag reduction characteristics of blade, wavy, sinusoidal, and herringbone riblet surfaces affected by different yaw angles. A precisely adjustable yaw angle measurement method was proposed based on a closed air channel. Our results revealed the aerodynamic behavior regularities of various riblet surfaces as affected by yaw angles and Reynolds numbers. Riblet surfaces with optimal air drag reduction were obtained in yaw angles ranging from 0 to 60°and Reynolds numbers ranging from 4000 to 7000. To evaluate the effects of the yaw angle, we proposed a criterion based on the actual spanwise spacing (d + ) of microstructure surfaces with the same phase in a near-wall airflow field. Finally, we established conceptual models of aerodynamic behaviors for different riblet surfaces in response to changes in the airflow direction. Our research lays a foundation for practical various riblet surface applications influenced by yaw angles to reduce air drag.