Phase inversion of slug flow on step surface to form high viscosity droplets in microchannel

Slug flow is a typical two phase flow in which droplets are lubricated by an immiscible continuous phase in a microchannel. The step surface is found to break the lubrication film and induce a phase inversion of the slug flow. The reduction in the film thickness by the step is quantitatively calculated and measured, and the critical droplet length for the breakup of the film is also revealed. This step-induced phase inversion is demonstrated to form high-in-low-viscosity emulsion droplets from a low-in-high-viscosity slug flow.