When droplets coalesce on a superhydrophobic nanostructured surface, the resulting droplet can jump from the surface due to the release of excess surface energy. If designed properly, these superhydrophobic nanostructured surfaces can not only allow for easy droplet removal at micrometric length scales during condensation but also promise to enhance heat transfer performance. However, the rationale for the design of an ideal nanostructured surface as well as heat transfer experiments demonstrating the advantage of this jumping behavior are lacking. Here, we show that silanized copper oxide surfaces created via a simple fabrication method can achieve highly efficient jumping-droplet condensation heat transfer. We experimentally demonstrated a 25% higher overall heat flux and 30% higher condensation heat transfer coefficient compared to state-of-the-art hydrophobic condensing surfaces at low supersaturations (<1.12). This work not only shows significant condensation heat transfer enhancement but also promises a low cost and scalable approach to increase efficiency for applications such as atmospheric water harvesting and dehumidification. Furthermore, the results offer insights and an avenue to achieve high flux superhydrophobic condensation.

Condensation on superhydrophobic nanostructured surfaces offers new opportunities for enhanced energy conversion, efficient water harvesting, and high performance thermal management. These surfaces are designed to be Cassie stable and favor the formation of suspended droplets on top of the nanostructures as compared to partially wetting droplets which locally wet the base of the nanostructures. These suspended droplets promise minimal contact line pinning and promote passive droplet shedding at sizes smaller than the characteristic capillary length. However, the gas films underneath such droplets may significantly hinder the overall heat and mass transfer performance. We investigated droplet growth dynamics on superhydrophobic nanostructured surfaces to elucidate the importance of droplet morphology on heat and mass transfer. By taking advantage of well-controlled functionalized silicon nanopillars, we observed the growth and shedding behavior of suspended and partially wetting droplets on the same surface during condensation. Environmental scanning electron microscopy was used to demonstrate that initial droplet growth rates of partially wetting droplets were 6× larger than that of suspended droplets. We subsequently developed a droplet growth model to explain the experimental results and showed that partially wetting droplets had 4-6× higher heat transfer rates than that of suspended droplets. On the basis of these findings, the overall performance enhancement created by surface nanostructuring was examined in comparison to a flat hydrophobic surface. We showed these nanostructured surfaces had 56% heat flux enhancement for partially wetting droplet morphologies and 71% heat flux degradation for suspended morphologies in comparison to flat hydrophobic surfaces. This study provides insights into the previously unidentified role of droplet wetting morphology on growth rate, as well as the need to design Cassie stable nanostructured surfaces with tailored droplet morphologies to achieve enhanced heat and mass transfer during dropwise condensation.

Water condensation on surfaces is a ubiquitous phase-change process that plays a crucial role in nature and across a range of industrial applications, including energy production, desalination, and environmental control. Nanotechnology has created opportunities to manipulate this process through the precise control of surface structure and chemistry, thus enabling the biomimicry of natural surfaces, such as the leaves of certain plant species, to realize superhydrophobic condensation. However, this "bottom-up" wetting process is inadequately described using typical global thermodynamic analyses and remains poorly understood. In this work, we elucidate, through imaging experiments on surfaces with structure length scales ranging from 100 nm to 10 μm and wetting physics, how local energy barriers are essential to understand non-equilibrium condensed droplet morphologies and demonstrate that overcoming these barriers via nucleation-mediated droplet-droplet interactions leads to the emergence of wetting states not predicted by scale-invariant global thermodynamic analysis. This mechanistic understanding offers insight into the role of surface-structure length scale, provides a quantitative basis for designing surfaces optimized for condensation in engineered systems, and promises insight into ice formation on surfaces that initiates with the condensation of subcooled water.