Micropillar structures exhibit significant potential for various applications, including enhanced heat transfer to anti-icing, corrosion resistance, oil-water separation, and droplet manipulation. There is still a lack of high-efficiency and high-flexibility methods for the texturing of micropillars on metallic surfaces. Elliptical vibration chiseling has emerged as a novel process for fabricating high-aspect-ratio microstructures on metals. Nevertheless, the achievable structural shapes are primarily limited to microribs. This study proposes a transverse-feeding vibration chiseling (TFVC) process for the ultrafast and flexible fabrication of micropillars. In TFVC, an inclined 1D vibration trajectory is in the cutting plane, and a triangular-shaped tool moves perpendicularly to the cutting plane, which differs from conventional vibration cutting. As a result, a chip is generated but left on the surface in each vibration cycle, forming a micropillar structure. Due to the shear deformation in the chip, the grain of the micropillar structure material can be modified to present different contact properties from the substrate material. A finite element simulation is performed to explore the underlying mechanics and predict the surface generation of micropillar structures. Then, surface experiments are conducted on aluminum to verify the efficacy of the TFVC and explore its deterministic process parameters. The experimental results show a successful fabrication of micropillars by the TFVC. Finally, fish-scale-type microstructures and hierarchical grooves have been fabricated to demonstrate process flexibility. Furthermore, lotus leaf-inspired superhydrophobic surfaces and structurally colored surfaces with self-cleaning functions have been developed to illustrate the application potential of the TFVC.
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