Cassie-Wenzel transition induced by localized freezing after droplet impact on supercooled micro-patterned surfaces

Micro-patterned surfaces have attracted significant attention in numerous applications owing to their potential to enhance hydrophobic and icephobic properties. A Cassie state of final wetting of a droplet upon impact on a micro-patterned surface, which is highly favorable for anti-icing applications, is achieved in this study through rapid localized freezing in the droplet-surface contact region via tuning the coupled interplay among droplet spreading kinetics, interfacial heat transfer, and solidification dynamics. Synchronized high-speed imaging and infrared thermography are employed to probe droplet impact and freezing dynamics, with particular emphasis on the transition of wetting state and its effect on the resulting freezing morphology. Experimental results reveal that variations in impact velocity and wall temperature lead to a final frozen wetting-state transition of the droplet from the Wenzel to the Cassie regime, accompanied by pronounced changes in freezing time, final spreading diameter, and frozen height. The transition of wetting states is attributed to rapid localized freezing at the droplet bottom, which suppresses liquid penetration into the micro-pattern. At lower impact velocities and surface temperatures, droplets tend to maintain the Cassie state with extended freezing durations, whereas higher velocities or higher temperatures promote rapid penetration and accelerated freezing. This study elucidates the coupled penetrating-freezing mechanism governed by micro-pattern design and provides fundamental insights into the rational design of anti-icing and icephobic surfaces.