Optimization of Hybrid Sol-Gel Coating for Dropwise Condensation of Pure Steam

We developed hybrid organic–inorganic sol–gel silica coatings with good durability in harsh environment (high temperatures, high vapor velocities) and with slightly hydrophobic behavior, sufficient to promote dropwise condensation (DWC) of pure steam. DWC is a very promising mechanism in new trends of thermal management and power generation systems to enhance the heat transfer during condensation as compared to film-wise condensation (FWC). The sol–gel coatings have been prepared from methyl triethoxy silane (MTES) and tetraethyl-orthosilicate (TEOS) and deposited on an aluminum substrate. The coatings were optimized in terms of precursor ratio and annealing temperature highlighting potentials and limits of such mixtures. A comprehensive surface characterization before and after saturated steam condensation tests has been performed and related to the thermal measurements for evaluating the heat transfer augmentation as compared to FWC obtained on untreated aluminum surfaces. The results showed that the developed hybrid organic-inorganic sol–gel silica coatings are promising DWC promoters.