Hierarchical microcavity topography for enhancement of water vapor condensation heat transfer by regulating droplet dynamics and droplet size distribution

Manipulating droplet dynamics is of great importance in condensation heat transfer enhancement. Cavity topography was believed to be able to regulate droplet merging and self-removal via Laplace force imbalance by the cavity wall and the effect of spatial confinement and isolation. However, the size effect of the microcavity on the droplet dynamics behavior, droplet size distribution and condensation heat transfer performance are not sufficiently understood. In this paper, hierarchical microcavity-arrayed superhydrophobic surfaces with a nominal cavity diameter of 20, 35, 50 and 70 μm were fabricated. Condensation experiments were first carried out in the atmosphere under an optical microscope, and then in pure steam in a self-designed environmental chamber at 4000 Pa. Local dynamic behaviors and time-lapsed evolutions of droplets during condensation were observed. Droplet size distribution and jumping rate were statistically analyzed using ImageJ software. It was proved the smaller cavity size of 20 μm is beneficial to facilitate condensate droplet jumping and increase the density of small droplets. The surface coverage ratio on the microcavity-arrayed superhydrophobic surfaces was only half of that on the hydrophobic surface at steady state. Enhancement of pure steam condensation heat transfer can be realized by effectively regulating droplet dynamics using microcavity topographies at limited subcooling degrees.