Grain Crystallinity, Anisotropy, and Boundaries Govern Microscale Hydrodynamic Transport in Semicrystalline Porous Media.

Polycrystallinity is often an unintended consequence of real manufacturing processes used to produce designer porous media with deterministic and periodic architectures. Porous media are widely employed as high-surface conduits for fluid transport; unfortunately, even small concentrations of defects in the long-range order become the dominant impediment to hydrodynamic transport. In this study, we isolate the effects of these defects using a microfluidic analogy to energy transport in atomic polycrystals by directly tracking capillary transport through polycrystalline inverse opals. We reveal─using high-fidelity florescent microscopy─the boundary-limited nature of flow motions, along with nonlinear impedance elements introduced by the presence of "grain boundaries" that are separating the well-ordered "crystalline grains". Coupled crystallinity, anisotropy, and linear defect density contribute to direction-dominated flow characteristics in a discretized manner rather than traditional diffusive-like flow patterns. Separating individual crystal grains' transport properties from polycrystals along with new probabilistic data sets enables demonstrating statistical predictive models. These results provide fundamental insight into transport phenomena in (poly)crystalline porous media beyond the deterministic properties of an idealized unit cell and bridge the gap between engineering models and the ubiquitous imperfections found in manufactured porous materials.

Boiling Heat Transfer with a Well-Ordered Microporous Architecture.

Boiling heat transfer through a porous medium offers an attractive combination of enormous liquid-vapor interfacial area and high bubble nucleation site density. In this work, we characterize the boiling performances of porous media by employing the well-ordered and highly interconnected architecture of inverse opals (IOs). The boiling characterization identifies hydrodynamic mechanisms through which structural characteristics affect the boiling performance of metallic microporous architecture by validating empirical measurements. The boiling performances can be optimized through the rational design of both the structural thicknesses and pore diameters of IOs, which demonstrate up to 336% enhancement in boiling heat-transfer coefficient (HTC) over smooth surfaces. The optimal HTC and critical heat flux occur at approximately 3-4 µm in porous structure thickness, which is manifested through the balance of liquid-vapor occupation within the spatial confinement of the IO structure. The optimization of boiling performances with varying pore diameters (0.3-1.0 µm) can be attributed to the hydraulic competitions between permeability and viscous resistance to liquid-vapor transport. This study unveils thermophysical understandings to enhance multiphase heat transfer in microporous media for ultrahigh heat flux thermal management.

Droplets on Slippery Lubricant-Infused Porous Surfaces: A Macroscale to Nanoscale Perspective.

A recent design approach in creating super-repellent surfaces through slippery surface lubrication offers tremendous liquid-shedding capabilities. Previous investigations have provided significant insights into droplet-lubricant interfacial behaviors that govern antiwetting properties but have often studied using macroscale droplets. Despite drastically different governing characteristics of ultrasmall droplets on slippery lubricated surfaces, little is known about the effects at the micro- and nanoscale. In this investigation, we impregnate a three-dimensionally, well-ordered porous metal architecture with a lubricant to confirm durable slippery surfaces. We then reduce the droplet size to a nanoliter range and experimentally compare the droplet behaviors at different length scales. By experimentally varying the lubricant thickness levels, we also reveal that the effect of lubricant wetting around ultrasmall droplets is intensely magnified, which significantly affects the transient droplet dynamics. Molecular dynamics computations further examine the ultrasmall droplets with varying lubricant levels or pore cut levels at the nanoscale. The combined experimental and computational work provides insights into droplet interfacial phenomena on slippery surfaces from a macroscale to nanoscale perspective.

Hierarchical and Well-Ordered Porous Copper for Liquid Transport Properties Control.

Liquid delivery through interconnected pore network is essential for various interfacial transport applications ranging from energy storage to evaporative cooling. The liquid transport performance in porous media can be significantly improved through the use of hierarchical morphology that leverages transport phenomena at different length scales. Traditional surface engineering techniques using chemical or thermal reactions often show nonuniform surface nanostructuring within three-dimensional pore network due to uncontrollable diffusion and reactivity in geometrically complex porous structures. Here, we demonstrate hierarchical architectures on the basis of crystalline copper inverse opals using an electrochemistry approach, which offers volumetric controllability of structural and surface properties within the complex porous metal. The electrochemical process sequentially combines subtractive and additive steps-electrochemical polishing and electrochemical oxidation-to improve surface wetting properties without sacrificing structural permeability. We report the transport performance of the hierarchical inverse opals by measuring the capillary-driven liquid rise. The capillary performance parameter of hierarchically engineered inverse opal ( K/ Reff = ∼5 × 10-3 µm) is shown to be higher than that of a typical crystalline inverse opal ( K/ Reff = ∼1 × 10-3 µm) owing to the enhancement in fluid permeable and hydrophilic pathways. The new surface engineering method presented in this work provides a rational approach in designing hierarchical porous copper for transport performance enhancements.

Controlled Wetting Properties through Heterogeneous Surfaces Containing Two-level Nanofeatures.

Addressing the direct control of surface wettability has been a significant challenge for a variety of applications from self-cleaning surfaces to phase-change applications. Surface wettability has been traditionally modulated by installing surface nanostructures or changing their chemistry. Among numerous nanofabrication efforts, the chemical oxidation method is considered a promising approach because it allows cost-effective, quick, and direct control of the morphologies and chemical compositions of the grown nanofeatures. Despite the wide applicability of the surface oxidation method, the precise control of wetting behaviors through the growth of nanostructures has yet to be addressed. Here, we investigate the wetting characteristics of heterogeneous surfaces that contain two-level features (i.e., nanograsses and nanoflowers) with different petal shapes and structural chemistry. The difference in growth rates between nanograsses and nanoflowers creates a time-evolving morphology that can be classified by grass-dominated or flower-dominated regimes, which induces a wide range of water contact angles from 120 to 20°. The following study systematically quantifies the structural details and chemistry of nanostructures associated with their wetting characteristics. This investigation of heterogeneous surfaces will pave the way for selective growth of copper nanostructures and thus a direct control of surface wetting properties for use in future copper-based thermal applications.