Vapor condensation is a well-known
phase-change phenomenon observed
in nature as well as in different industrial applications. Superhydrophobic
surfaces (SHSs) with low hysteresis can efficiently drain off the
condensate and rejuvenate the nucleation sites further. In this work,
three distinct SHSs were fabricated by nanocoating three hydrophobic
agents, viz., perfluoro-octyl-triethoxy-silane (PFOTS), perfluoro-octanoic-acid
(PFOA), and commercial Glaco solution on a hierarchical aluminum surface.
The surface morphology of all surfaces was investigated, and its effects
on the wetting, droplet departure, and overall heat-transfer coefficient
(HTC) during condensation phenomena in the humid air (>95% noncondensable
gases) were analyzed. The contact angle hysteresis of all three surfaces
was very low (∼5°); however, different wetting behaviors
were observed during the condensation, depending on the adhesion of
the condensate drop with nanoscale textures in the microcavities.
Dropwise condensation (DWC) was observed in silane and Glaco-coated
surfaces. A gravity-assisted sweeping mechanism removed the condensate
from the silane-coated surface. In contrast, the condensate was ejected
out of the plane of the Glaco-coated surface by droplet jumping. The
PFOA-coated surface has shown DWC initially and floods in the later
stages due to highly pinned condensed droplets. This study reports
an enhancement of ∼35 to ∼110% in the HTC for the SHS-exhibiting
gravity-assisted sweeping mechanism compared to the droplet-jumping
mechanism. The present work will provide substantial insights into
the fabrication of efficient hierarchical interfaces for water-energy
nexus applications.