Solidification, Melting, Casting, Welding, Interfacial interactions phenomena, Evaporation, Crystallization during evaporation, Boiling, Flow visualization, Transport Phenomena, Natural convection, Experimental Fluid Dynamics and Heat Transfer, Phase change process, Phase change materials.
28
Scopus Publications
Scopus Publications
Salt Creeping and Crystal Lifting in Ternary Droplets on Hydrophobic Substrates Narendra Ch. Kumar, Virkeshwar Kumar Langmuir, 2026 Salt creeping during evaporative crystallization is generally associated with hydrophilic substrates, where capillary spreading of the saline solution promotes lateral crystal growth. In contrast, hydrophobic surfaces are typically expected to suppress such spreading. Here, we demonstrate the unexpected and sustained occurrence of salt creeping on both hydrophobic and superhydrophobic substrates during the evaporative crystallization of ternary saline droplets. To establish the generality of this phenomenon, multiple ternary systems are investigated, including water–NaCl–KCl, water–NaCl–KNO3, water–NaCl–NH4Cl, water–KCl–KNO3, water–KCl–NH4Cl, and water–KNO3–NH4Cl, over a broad substrate temperature range of 40–135 °C. Detailed experiments with water–NaCl–KCl mixtures on heated substrates reveal distinct creeping deposition patterns and crystal lifting, accompanied by systematic changes in contact angle, deposit height, and lateral footprint. Morphological analysis shows that ternary crystallization promotes elongated and hopper-type crystals that form interconnected porous networks rather than simple cubic structures. These networks act as efficient capillary pathways, sustaining liquid transport and enabling lateral redistribution of the solution, even on hydrophobic substrates. A local mass-balance between the capillary wicking flux and crystallization indicates that the extent of creeping is governed by the competition between these two processes. At elevated temperatures, this balance shifts, producing a transition from dominant creeping to a mixed regime of creeping and crystal lifting, revealing distinct temperature-dependent deposition behavior. Overall, this work proposes a generalized mechanism based on capillary-driven mass flux to explain salt creeping on hydrophobic substrates and highlights the critical role of crystal morphology in controlling liquid transport and deposit evolution during multicomponent evaporative crystallization.
Multicomponent Droplet Crystallization: Latent Heat Release and Bubble Formation Narendra Ch. Kumar, Virkeshwar Kumar Langmuir, 2025 Bubble formation in evaporating saline droplets at subboiling temperatures is a striking and nonintuitive phenomenon that challenges conventional understanding of phase change processes. In this study, the mechanisms of bubble formation are systematically investigated in ternary saline droplets (water + two salts) with different combinations of high- and low-latent heat of solid formation (LHSF) salts, which can potentially be extended to multicomponent systems encompassing all possible combinations. The results reveal that bubble formation is not governed solely by the LHSF but also critically by the rate at which this latent heat is released. Real-time imaging is employed to capture the onset of nucleation, crystal growth, and bubble evolution, while in situ thermocouple measurements provide direct evidence of transient thermal fluctuations. A one-dimensional energy balance at the solid-liquid interface demonstrates that the governing parameter is not LHSF alone but the combined influence of latent heat release and the kinetics of crystal growth. Bubble formation is consistently observed in droplets containing high-LHSF salts as well as in high-high and high-low LHSF combinations, the latter mainly due to the presence of high-LHSF salts. Remarkably, certain low-low LHSF systems also produce bubbles when crystallization proceeds at sufficiently high growth rates. These findings establish that bubble formation arises from the interplay between the thermodynamic magnitude (LHSF) and the kinetic rate (growth), thereby proposing a generalized mechanism for this unusual phenomenon.
Successive solidification and melting of binary salt-water system: Convection and double-diffusive layer formation Radhika Sarawagi, Virkeshwar Kumar Physics of Fluids, 2025 The dynamics of successive solidification and melting in binary salt systems are governed by intricate interactions between thermal and solutal convection, mushy zone evolution, and density stratification. While prior studies have examined double-diffusive convection in salt–water systems, the successive pathways of solidification and melting—particularly the staged life cycle of double-diffusive layer (DDL) formation during melting—remain unexplored. In this study, the phase-change behavior of water–NH4Cl solutions at hypo-, eutectic-, and hyper-eutectic compositions is investigated using in situ digital single-lens reflex imaging, shadowgraph visualization, thermocouple measurements, concentration sampling, and validated numerical simulations with user-defined functions in ANSYS Fluent. Solidification in the hypo-eutectic regime is dominated by strong thermosolutal convection, leading to mushy zone growth, solute accumulation, and eventual bridging, while melting generates transient DDLs and wavy interfaces. In the eutectic regime, solidification proceeds in an orderly manner without mush formation, governed by stable thermal convection rolls and a prolonged isothermal plateau, whereas melting is rapid, highly convective, and marked by temperature oscillations and vigorous interface variation. The hyper-eutectic regime exhibits dendritic NH4Cl growth, dendrite fragmentation, and preferential eutectic front formation during solidification, while melting proceeds asymmetrically from eutectic-rich top regions, producing stratified DDLs that extend downward in a filling-box mechanism. The staged life cycle of DDL formation—onset, preferential top melting, layered stratification, and eventual merging—is established for the first time in binary melting. This work provides the first mechanistic framework for understanding DDL-driven successive solidification and melting in multicomponent phase-change systems, with implications for desalination, thermal energy storage, and alloy solidification.
Drop spreading characteristics over a micro-pillared surface and comparison with an equivalent flat surface C. Ramgopal, K. Muralidhar, Virkeshwar Kumar Physics of Fluids, 2025 Low-Weber-number droplet impacts (We < 1) are crucial in applications such as dropwise condensation, microfluidics, inkjet printing, and spray coating where surface tension is dominant. The present study investigates the spreading of millimetric droplets on micro-pillared surfaces with varying pitch (15, 30, and 60 μm) and Weber numbers (0.21, 1, and 3.9), encompassing capillary, transition, and inertia-dominated regimes. Experimental observations reveal distinct jet ejection regimes, including transitions from entrapped jets to singular thin jets with increasing Weber numbers. Multiple bouncing was observed on sparsely spaced pillars at lower Weber numbers. A numerical model employing an equivalent flat surface approximation, incorporating a dynamic contact angle model for a pillared surface, was utilized to obtain droplet shapes and spreading patterns. This approach successfully predicted droplet deformation in the capillary and inertia-dominated regimes. To account for the influence of liquid penetration into the pillar spacing at higher impact velocities, the contact angle parameters were suitably modified, resulting in improved agreement between simulations and experiments across all impact regimes. These findings highlight the importance of liquid penetration between pillars for accurately predicting wetting state transitions during droplet impact dynamics on micro-pillared surfaces.