This project was carried out for an advanced research facility development center to investigate the behavior of microdroplets impacting engineered microstructured and superhydrophobic surfaces under extreme thermal conditions. High-resolution multiphase CFD simulations were developed to capture droplet impact, spreading, recoil, rebound, and subsequent phase-change behavior.
Two important operating scenarios were investigated. For heated surfaces, the simulations captured droplet heating, boiling, vapor generation, and the way thermal conditions influence contact and rebound behavior. For cold surfaces, the analysis reproduced progressive droplet solidification and freezing after impact, including the formation and evolution of the mushy zone as the liquid transitioned toward the solid phase.
The simulations provided detailed insight into how surface microstructure, wettability, impact dynamics, and thermal conditions interact during rapid microscale phase change. This capability is particularly valuable for research and technology development involving spray cooling, anti-icing and icing control, thermal management, coating processes, microfluidics, and engineered functional surfaces.
The project also demonstrates the potential of advanced CFD thermal-management analysis to evaluate complex transient phase-change processes before extensive fabrication and experimental testing.
Contact CFD Vision to discuss advanced multiphase CFD, droplet phase-change simulation, or research-facility development projects.