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We experimentally study the transition from droplet to wave regimes in microfluidic liquid–liquid multiphase flows having large differences in viscosity. A unified approach based on periodic pattern analysis is employed to study relationships between dispersed and separated flow regimes, including dripping, jetting, capillary waves, inertial waves and core–annular flows over a wide range of flow rates and viscosity contrasts. We examine the morphology and dynamics of each flow regime based on wavelength, frequency and velocity of repeating unit cells to elucidate their connections and to develop predictive capabilities based on dimensionless control parameters. We demonstrate in particular that pattern selection is contingent upon the propagation velocity of droplets and waves at the transition. We also investigate microfluidic wave breaking phenomena with the formation of ligaments and droplets from wave crests in both capillary and inertial wave regimes. This work expands conventional multiphase flow regimes observed in microchannels and shows new routes to disperse highly viscous materials using interfacial waves dynamics in confined microsystems. 

In this work, we study the spontaneous spreading of water droplets immersed in oil and report an unexpectedly slow kinetic regime not described by previous spreading models. We can quantitatively describe the observed regime crossover and spreading rate in the late kinetic regime with an analytical model considering the presence of periodic metastable states induced by nanoscale topographic features (characteristic area ~4 nm², height ~1 nm) observed via atomic force microscopy. The analytical model proposed in this work reveals that certain combinations of droplet volume and nanoscale topographic parameters can significantly hinder or promote wetting processes such as spreading, wicking, and imbibition.