Research Progress on Droplet Impact Behavior on Superhydrophobic Surfaces

XIA Lei; CHEN Faze; CHEN Xiaokang; ZHOU Jianping

doi:10.16490/j.cnki.issn.1001-3660.2025.21.003

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Surface Technology ›› 2025, Vol. 54 ›› Issue (21) : 47-63. DOI: 10.16490/j.cnki.issn.1001-3660.2025.21.003

Special Topic—Design and Applications of Hierarchical Surface Structure Exhibiting Superwettability

Research Progress on Droplet Impact Behavior on Superhydrophobic Surfaces

XIA Lei^1a,1b, CHEN Faze², CHEN Xiaokang^1a, ZHOU Jianping^1a,*

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Abstract

The dynamic behavior of droplet impact on solid surfaces is a fundamental phenomenon that occurs widely in both nature and industrial applications. It plays a critical role in various engineering and scientific domains, including fluid mechanics, interfacial physics, and microscale heat and mass transfer. In recent years, bioinspired superhydrophobic surfaces, characterized by their extreme water-repellent properties due to micro- and nano-scale structures, have garnered increasing attention owing to their promising applications in condensation heat transfer, anti-icing, anti-corrosion, drag reduction, and self-cleaning technologies. Consequently, the study of droplet impact dynamics on superhydrophobic surfaces has become a research hotspot.
This review focuses on the recent advances in understanding the complex droplet impact behavior on superhydrophobic surfaces. Firstly, the fundamental impact phases including spreading, retraction, splashing, and rebound are systematically introduced. The effect of key impact parameters such as droplet diameter, viscosity, impact velocity, surface roughness, and static contact angle on the impact dynamics is discussed in detail. These parameters collectively determine the kinetic energy dissipation, wetting behavior, and ultimate rebound performance of the droplet.
Subsequently, the formation, evolution, and breakdown of the thin air film between the droplet and the substrate during the early stage of impact are analyzed, alongside current experimental techniques for visualizing nanoscale gas layers. The stability and rupture mechanisms of the air film are revealed to be crucial in determining whether the impact is non-wetting or results in liquid-solid contact. The contact modes of droplets on smooth and rough surfaces are further discussed, shedding light on the interplay between kinetic energy and surface energy during the impact process.
In terms of surface design and preparation, this review summarizes the typical fabrication strategies for superhydrophobic surfaces, including chemical etching, lithography, self-assembly, and low surface energy coating. Based on the wettability transition mechanism, the conditions for transitions from non-wetting (Cassie-Baxter state) to partial or full wetting (Wenzel state) are explored, considering factors such as impact-induced pressure and energy dissipation. The role of surface micro/nanostructures in controlling the contact time and bounce behaviors is emphasized. Particular attention is given to the mechanisms behind unconventional rebound phenomena, such as pancake bouncing and angular or toroidal bouncing, which offers novel possibilities for controlling droplet-surface interactions.
Moreover, the review highlights a series of complex secondary phenomena during droplet impact, including contact time minimization, air cavity collapse leading to upward jet formation, entrapped air bubble generation, and asymmetric rebounds induced by surface heterogeneity or inclination. The underlying mechanisms, associated dimensionless parameters (e.g., Weber number, Reynolds number, Ohnesorge number), and scaling laws governing these behaviors are critically reviewed.
Finally, current challenges and research gaps are outlined, including the lack of accurate models for multiphase interactions, limited understanding of impact dynamics under extreme environmental conditions (e.g., high temperature, low temperature, humidity, or low pressure), and insufficient exploration of real-world engineering integration. Future studies should aim to strengthen interdisciplinary collaboration, combine experimental, theoretical, and computational approaches, and accelerate the transition from laboratory research to practical applications.
This review aims to provide comprehensive theoretical insights and practical guidelines for researchers and engineers engaged in the study and application of droplet dynamics on superhydrophobic surfaces.

Key words

droplet impact / superhydrophobic surface / dynamic behavior / wetting transition

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XIA Lei, CHEN Faze, CHEN Xiaokang, ZHOU Jianping. Research Progress on Droplet Impact Behavior on Superhydrophobic Surfaces[J]. Surface Technology. 2025, 54(21): 47-63 https://doi.org/10.16490/j.cnki.issn.1001-3660.2025.21.003

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