Liquid-infused surfaces for mitigation of corrosion and inorganic scaling

Abstract

In this study, the effectiveness of a binary surface (BiS), a type of liquid-infused surface, in enhancing corrosion resistance and mitigating inorganic fouling without compromising heat exchange efficiency is demonstrated. An Ultra-Omniphilic Surface (UOS) was initially prepared from a plain aluminum alloy surface (PS) using a bulk micro-manufacturing approach. Subsequently, the sub-surface micro/nanocavities of UOS were infused with a liquid lubricant to create BiS, characterized by two distinct superficial phases — solid islands and liquid puddles. Lab-scale experiments in a simulated brackish water environment revealed that BiS outperformed both PS and UOS in inhibiting scaling and corrosion. The BiS exhibited nearly 50% less mass gain due to mineral deposition than PS and UOS. Moreover, corrosion rates obtained from electrochemical and immersion tests indicated significantly slower metal degradation on BiS compared to PS and UOS. Furthermore, BiS displayed superior heat exchange capabilities, collecting approximately 73% and 44% more condensate than PS and UOS, respectively. This enhancement is attributed to well-distributed liquid puddles on BiS, promoting a smooth, defect-free surface that reduces foulant adhesion and shields the underlying metal from corrosion, while also enhancing two-phase heat transfer activity. © 2024 Elsevier Ltd