Cascade coalescence dynamically sustains bubble retention near gas-evolving surfaces

Abstract

Bubble detachment from solid surfaces governs heat, mass, and charge transport across technologies vital to clean energy, including high-current-density water electrolysis and boiling thermal management. At high gas fluxes, however, bubbles remain trapped at active surfaces despite immense buoyancy, severely restricting mass transfer and increasing energy losses. Here, we show that this unexpected surface retention originates from cascade coalescence between unequal-sized bubbles. High-speed observations around microelectrodes demonstrate that when a rising bubble merges with a smaller surface-attached successor, its trajectory abruptly reverses, accelerating toward the substrate at nearly two orders of magnitude above its rising speed. Direct numerical simulations and scaling analysis reveal that asymmetric interfacial retraction during merging generates non-canceling viscous stresses, producing a net downward impulse toward the smaller bubble. Repeated cascade coalescence events accumulate these transient impulses into a steady, time-averaged retaining force capable of opposing buoyancy three to four orders of magnitude beyond quasistatic limits. Our findings establish bubble coalescence as a previously unrecognized mechanism that dynamically sustains bubble retention under high gas flux.