Investigating Droplet Impact Dynamics on Engineered Surfaces: Effects of Roughness, Wettability, and Prospects for Anti-Icing Applications

Understanding how water droplets interact with engineered surfaces can help address critical challenges such as ice accumulation on airplanes, wind turbines, and power lines, which can pose safety risks and result in costly damage. This research examines how surface properties, including roughness and water-repellent coatings, influence the behavior of droplets as they spread, rebound, or freeze. By utilizing high-speed imaging techniques, the study captured droplet behavior on various materials, identifying key surface design features that improve water repellency. To ensure these surfaces can endure real-world conditions, the study introduced innovative imaging and durability testing protocols. Using 3D profiling, the research tracked microscopic changes in surface structures over time and under stress, such as scratching, peeling, and chemical exposure. These tests identified critical points where surfaces start to lose their water-repellent and anti-icing properties, providing valuable insights into how to enhance material durability. The work also developed a custom-built Supercooled Box Device to simulate extreme freezing conditions, such as freezing rain, and test surface performance in controlled environments. This tool serves as a base for future investigations into how superhydrophobic surfaces (SHS) can be optimized for anti-icing applications, offering a modular platform to explore freezing droplet dynamics and assess surface effectiveness in realistic, controlled conditions. By combining droplet impact analysis, durability testing, and experimental facilities, this research provides a comprehensive framework for creating surfaces that are both highly effective at repelling water and robust enough to endure harsh environments. The findings have significant implications for advancing safer and more sustainable technologies in aviation, energy, and infrastructure industries.