Mechanisms in Droplet Impact on Rough Surfaces with Spontaneously Varying Viscosity

Polyurea, a novel spray-applied composite polymer, is of high application importance for rapid roadway support in coal mines. The current study investigates the dynamic process and mechanisms governing the impact and spreading of polyurea droplets on rough surfaces through experimental and theoretical approaches. The key novelty lies in revealing how spontaneously varying viscosity couples with surface microstructure to produce novel scaling laws distinct from classical Newtonian behavior. The droplet impact and wetting process can be divided into three stages. In the pinning stage, droplet behavior is dominated by kinetic energy, leading to inertia-driven spreading in which the contact line radius increases quite slowly with time. In the penetration stage, the apparent three-phase contact line (TPCL) is pinned by surface microstructures, while the real TPCL evolves with time following a temporal scaling law t3/2. In the spreading stage, surface roughness becomes decisive. On low-roughness substrates, limited pinning allows the real and apparent TPCLs to spread synchronously, with TPCL evolution governed by surface tension and viscous forces, following a t1/8 scaling law. As roughness increases, pinning effects strengthen, causing divergence: the real TPCL is driven by surface tension and viscous dissipation between microstructures, whereas the apparent TPCL is additionally influenced by pinning and reaction-induced viscosity, scaling as t1/24. This t1/24 scaling for the apparent contact line on relatively high-roughness surfaces represents a significant deviation from established scaling relations. Experiments on rock-like substrates confirm these mechanisms for polyurea droplets. These findings provide theoretical and engineering guidance for optimizing spray-coating parameters in coal mines, with the goal of improving coating uniformity and interfacial adhesion.