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Simulation and experiment of WEDM double-scale array microstructure surface wetting performance

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Abstract

To address the problems of high process complexity, uncontrollable and unpredictable wetting performance, and expensive processing equipment for the superhydrophobic surfaces of metal substrates prepared by conventional methods, in this paper, superhydrophobic surfaces consisting of rectangular cross-section double-scale arrays of microstructure were prepared on HT250 substrates using wire electrical discharge machining (WEDM). First, a simulation model of the surface wetting performance of the rectangular cross-section double-scale array microstructure prepared by WEDM is established, to analyze the effect of peak current and pulse width on the surface roughness, dimensional parameters, and surface wetting performance of the discharge micro-crater structure; the effect of the width and distance of the rectangular cross-section on the surface wetting performance of the double-scale array of microstructure with rectangular cross-section is further discussed. And the simulation model is experimentally verified. The results of the study in this paper indicate that at a peak current of 12A, a pulse width of 20 μs, and a rectangular cross-section with a width and distance of 200 μm, the contact angles of the rectangular cross-section double-scale array microstructure surface obtained from simulation and experiment are 133° and 135.3°, respectively, the prediction accuracy of the simulation model is 98.3%, and the surface has superhydrophobic performance after low surface energy treatment, with a static contact angle of 151.5°. This study not only extends the application area of WEDM, but also provides a theoretical reference for the design of metal substrate microstructure surface, realizes the controllable preparation and accurate prediction of wetting performance of metal substrate microstructure surface, and has important guiding significance for the preparation of metal substrate superhydrophobic surfaces.

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Abbreviations

W :

Width of rectangular cross-section (μm)

L :

Distance of rectangular cross-section (μm)

h :

Depth of a single discharge micro-crater (μm)

r :

Radius of a single discharge micro-crater (μm)

h a :

Height of the raised structure relative to the bottom (μm)

a :

Diameter of the raised structure (μm)

r s :

Remaining radius after superposition of single discharge micro-crater (μm)

b :

Distance between two raised structures (μm)

h b :

Height of the highest point of the remaining part of a single discharge micro-crater after superimposition from its bottom (μm)

Ra :

Surface roughness of discharge micro-crater structure (μm)

θ c :

Contact angle of the surface of a discharge micro-crater structure in the Cassie wetting state (°)

f 1 :

Solid-liquid contact area on the surface of the discharge micro-crater structure as a fraction of the actual contact area of the liquid droplet

θ 0 :

Intrinsic contact angle of the substrate surface (°)

ρ :

Density of the fluid (Kg/m3)

u :

Flow rate of fluid (m/s)

P :

Pressure of the fluid (Pa)

I :

Unit Matrix

μ :

Dynamic viscosity of the fluid (kg/m/s)

T :

Temperature of the fluid (K)

F :

Volumetric force source term (N)

ϕ :

Phase-field variables

ε :

Interface thickness control parameters (m)

ψ :

Phase-field auxiliary variables

σ :

Surface tension coefficient (mN/m)

λ :

Hybrid energy density (J/m3)

ρ 1 :

Density of air (Kg/m3)

ρ 2 :

Density of water (Kg/m3)

μ 1 :

Dynamic viscosity of air (kg/m/s)

μ 2 :

Dynamic viscosity of water (kg/m/s)

V f 1 :

Volume fraction of air

V f 2 :

Volume fraction of water

θ c ' :

Contact angle of rectangular cross-section double-scale array microstructure surface in the Cassie wetting state (°)

f 1 ' :

The share of the solid–liquid contact area on the surface of the microstructure array with rectangular cross-section in the actual contact area of the liquid droplet

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Funding

This work was supported by the Supported by Opening Project of the Key Laboratory of Advanced Manufacturing and Intelligent Technology (Ministry of Education), grant number: KFKT202204, and National Natural Science Foundation of China, grant number: 52075134.

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Authors and Affiliations

  1. Key Laboratory of Advanced Manufacturing Intelligent Technology of Ministry of Education, Harbin University of Science and Technology, Harbin, 150080, Heilongjiang Province, China

    Zhaolong Li

  2. School of Mechanical and Power Engineering, Harbin University of Science and Technology, Harbin, 150080, Heilongjiang Province, China

    Zhaolong Li, Wangwang Li, Yingtao Liu, Meng Xun & Mengchen Yuan

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Contributions

Zhaolong Li: conceptualization, methodology, software. Wangwang Li: data curation, writing—original draft preparation. Yingtao Liu: visualization, investigation. Meng Xun: supervision, software. Mengchen Yuan: writing—reviewing and editing. All authors commented on previous versions of the manuscript. All authors read and approved the final manuscript.

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Correspondence to Zhaolong Li.

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Li, Z., Li, W., Liu, Y. et al. Simulation and experiment of WEDM double-scale array microstructure surface wetting performance. Int J Adv Manuf Technol 126, 3205–3218 (2023). https://doi.org/10.1007/s00170-023-11331-2

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  • DOI: https://doi.org/10.1007/s00170-023-11331-2

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