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Ultra-resilient multi-layer fluorinated diamond like carbon hydrophobic surfaces

AbstractSeventy percent of global electricity is generated by steam-cycle power plants. A hydrophobic condenser surface within these plants could boost overall cycle efficiency by 2%. In 2022, this enhancement equates to an additional electrical power generation of 1000 TWh annually, or 83% of the global solar electricity production. Furthermore, this efficiency increase reduces CO2 emissions by 460 million tons /year with a decreased use of 2 trillion gallons of cooling water per year. However, the main challenge with hydrophobic surfaces is their poor durability. Here, we show that solid microscale-thick fluorinated diamond-like carbon (F-DLC) possesses mechanical and thermal properties that ensure durability in moist, abrasive, and thermally harsh conditions. The F-DLC coating achieves this without relying on atmospheric interactions, infused lubricants, self-healing strategies, or sacrificial surface designs. Through tailored substrate adhesion and multilayer deposition, we develop a pinhole-free F-DLC coating with low surface energy and comparable Young’s modulus to metals. In a three-year steam condensation experiment, the F-DLC coating maintains hydrophobicity, resulting in sustained and improved dropwise condensation on multiple metallic substrates. Our findings provide a promising solution to hydrophobic material fragility and can enhance the sustainability of renewable and non-renewable energy sources.
Publications

Site-selective modification of metallic nanoparticles

Surface patterning of inorganic nanoparticles through site-selective functionalization with mixed ligand shells or additional inorganic material leads to tailored nanomaterials with potentially novel and/or multifunctional properties.

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This project is supported by U.S. National Science Foundation under the Materials Research Science and Engineering Centers (MRSEC) program. Any opinions, findings, conclusions, or recommendations expressed in this material are those of the authors and do not necessarily reflect the views of the U.S. National Science Foundation or the participating institutions. This site is maintained collaboratively by principal investigators with NSF MRSEC awards, independent of NSF.