Superhydrophobic Aluminum Research Articles

Superhydrophobic Modification of Atomic Layer Deposition Antireflection Aluminum Oxide Film: A Simple Evaporative Coating Technique.

The antireflective transmittance-enhancing films have important applications in solar cells and other applications due to their self-cleaning and high light transmittance. However, obtaining high transmittance, highly durable, and superhydrophobic surfaces in a simple and easily accessible way is still a challenge. A simple evaporative coating technique has been proposed that can be used to prepare antireflective superhydrophobic aluminum oxide films using 1H,1H,2H,2H-perfluoroalkyltriethoxysilanes. The results show that the contact angle of grass-like alumina increased from 99.5° to 155°. The surface energy of grass-like alumina decreased from 17.96 to 1.93 mN/m. The maximum value of light transmittance is close to 98%, and the average transmittance is above 95%. The films have excellent ultraviolet resistance and thermal stability along with relative mechanical and chemical stability. Meanwhile, this method has an excellent capacity for shape preservation. The relationships between the evaporation temperature and time and the light transmittance and hydrophobic angle of the films were also investigated together. This approach has the potential to be extended to large-scale industrial production.

Anti-corrosion and anti-icing properties of superhydrophobic laser-textured aluminum surfaces

Superhydrophobic surfaces have favorable properties in simultaneously reducing the negative effects of corrosion and ice accumulation. In this study, laser-texturing was employed as a facile and environmentally friendly surface method to prepare a surface with hierarchical roughness for subsequent grafting by immersion in an ethanol solution containing 1H,1H,2H,2H-perfluorodecyltriethoxysilane (FAS-10). Various analytical techniques were utilized to assess the characteristics of the laser-textured aluminum surfaces before and after grafting, such as a contact profilometer, optical tensiometer, scanning electron microscope with energy-dispersive spectroscope, and X-ray photoelectron spectroscope. These methods were used to evaluate surface roughness, wettability, morphology, and composition. The corrosion properties were evaluated through potentiodynamic and impedance measurements in a dilute Harrison's solution (DHS) composed of 0.35 wt% (NH4)2SO4 + 0.05 wt% NaCl. Additionally, freezing delay tests at various surface temperatures were performed to assess the surface's ability to prevent the freezing of water droplets on the treated surface. The laser-textured aluminum surface, featuring micro/nanostructures and a grafted nanoscopic perfluoroalkyl silane film, exhibited outstanding superhydrophobicity and enhanced corrosion protection. The developed surface has been shown to significantly delay the onset of ice nucleation and extend the freezing delay.

Mechanical and anti-icing performance of superhydrophobic aluminum conductor by anodized oxide technique

Abstract Anodized oxide technology is a traditional surface treatment method used in the material engineering field to enhance the friction, anti-icing, anti-corrosion, and insulation properties of Al-based samples. Considering the anti-icing and insulation performance, anodized oxide technology has great application prospects in overhead transmission lines. In this study, the preparation process of Aluminum (Al) flat plates and Aluminum Cable Steel-Reinforce (ACSR) was explored by using anodizing technology to obtain superhydrophobic properties. Moreover, as the significant performance in the application of transmission lines, the mechanical performance (tensile strength) of Al conductors was evaluated to study the impact of anodized oxidation technology. The results show that anodized oxide technology can improve the tensile strength of aluminum clad steel bars and aluminum-stranded wires in ACSRs. In addition, the hydrophobicity and anti-icing performance of anodized wires can demonstrate potential application prospects in the field of anti-icing.

Long-term superhydrophobic, antibacterial, and corrosion-resistant Ag-loaded LiAl-LDH composite coating grown in-situ on MAO coating

This study successfully prepared long-term superhydrophobic, antibacterial, and corrosion-resistant lithium aluminum layered double hydroxide (LiAl-LDH) modified with 1H,1H,2H,2H-perfluorooctyltriethoxysilane (PFOTES) through a hydrothermal reaction. The LiAl-LDH was in situ grown on the micro-arc oxidation (MAO) film and loaded with Ag nanoparticles. The results showed that at a hydrothermal reaction temperature of 150 °C, LiAl-LDH effectively filled the microscopic defects of the MAO coating, significantly enhancing its hydrophobicity. After PFOTES treatment, the water contact angle remained above 150° even after 75 days of immersion in simulated seawater. Additionally, the introduction of Ag+ notably improved the antibacterial properties of the coating. Electrochemical tests indicated that the corrosion resistance of the coating increased with higher hydrothermal temperatures. The corrosion current density of the coating obtained at 150 °C was measured at 2.30 × 10−9 A∙cm−2, which is two orders of magnitude lower than that obtained at 100 °C. Following hydrophobic modification, the corrosion current density decreased further, and after 50 days of immersion in simulated seawater, the |Z|0.01Hz value remained above 108 Ω·cm2, demonstrating excellent corrosion resistance. This study provides important experimental and theoretical foundations for developing metal surface protective coatings with broad application prospects.

Durable Superhydrophobic Aluminum Surfaces against Immersion and Hot Steam Impact: A Comparative Evaluation of Different Hydrophobization Methods and Coatings

Controlling the wettability properties of metallic materials and surfaces can enhance their applicability and improve their performance and durability in several fields, such as corrosion protection, heat transfer applications, self-cleaning, and friction reduction. Here, we present and compare some versatile fabrication methods that can provide aluminum surfaces with durable superhydrophobic performance which are suitable for heat transfer applications. To probe their stability in heat transfer applications, two evaluation protocols are designed, one which suggests immersion in hot water for several hours, and a second testing against the harsh conditions of hot steam impact. The superhydrophobic aluminum surfaces are fabricated by first creating micro or micro-nano roughness on an initially flat surface, followed by the minimization of its surface energy through two hydrophobization methods, one wet and one dry, thus creating a series of different coating materials. Surfaces are then evaluated by immersing them in hot water and exposing them to steam impact. It is demonstrated that despite the fact that all hydrophobization methods tested resulted in surfaces exhibiting superhydrophobic properties, only the ultra-thin Teflon-like coating, obtained after plasma deposition using C4F8 plasma, exhibited robust superhydrophobicity with hysteresis lower than 8° when immersed in water at 90 °C for 10 h. This surface also showed minimal wettability changes and was the only one to retain its hysteresis below 6° after 4 h of exposure to hot steam.

Superhydrophobic performance of aluminum textured with a picosecond laser

Aluminum is a common and light engineering metal with high strength, good processability, corrosion resistance, high electrical conductivity, and strong recyclability, properties that allow its wide use in different fields. Strengthening the surface properties of aluminum materials can not only enable aluminum materials to be applied to complex environments but also extend their service life. In this study, two kinds of micro–nano structures—unidirectional micro-grooves and grid micro-grooves—were prepared on the surface of 1060 aluminum using picosecond-laser direct etching, so that its surface can attain superhydrophobic properties and enhance its application performance. The effect of the scanning interval of picosecond laser on the hydrophobic performance was investigated, and the findings indicate that the hydrophobic properties are most effective by using scanning interval of 20 μm. The scanning electron microscope (SEM) and atomic force microscope (AFM) analyses revealed the formation of a micro-nano structure resembling nanoflower particles on the laser-treated aluminum surface, which contributed to increased surface roughness. EDS analysis indicated an increase in carbon (C) content, likely due to the adsorption of organic molecules from the air, which further promoted hydrophobicity. X-ray diffraction spectrometry (XRD) and X-ray photoelectron spectroscopy (XPS) provided insights into the surface chemistry and the presence of various elements and compounds. The superhydrophobic aluminum surfaces demonstrated remarkable stability and self-cleaning capabilities, desirable traits for many practical applications. This study provides a simple and rapid method for preparing superhydrophobic materials on aluminum surfaces and has potential practical application value.This innovation paves the way for the development of high-performance aluminum materials suitable for a wide range of environments and uses.

Acid wet blasting method for fabricating superhydrophobic aluminum surface with micro-nano composite structures

Acid wet blasting method for fabricating superhydrophobic aluminum surface with micro-nano composite structures

Degradation of superhydrophobic aluminium overhead line conductor surfaces

AbstractIt has been shown that noise emissions from HV overhead line conductors can be reduced under rain conditions by making their surfaces superhydrophobic. The working environment makes ensuring the longevity of any treatment a major challenge. The degradation of various superhydrophobic surfaces generated by applying a superhydrophobic coating and patterning microscale channels is assessed under an AC electric field (18 kV/cm) with continuous water spray. By examining the droplet distribution on the surfaces during the degradation and the surface roughness before and after degradation, the authors demonstrate that no water droplets were found on the microscale patterned surface, but droplets were formed on the coated surface after degradation. The surface roughness reduction of the coated surface and microscale patterned surface was 29.8% and 11.3%, respectively, indicating that the microscale patterned surface has better durability than the superhydrophobic coating under the AC electric stress.

Fabrication of superhydrophobic aluminum alloy surfaces by nickel and phosphorus chemical deposition

Fabrication of superhydrophobic aluminum alloy surfaces by nickel and phosphorus chemical deposition

Preparation of mechanically durable superhydrophobic aluminum surfaces by LST/MAO and chemical modification

In this paper, a superhydrophobic surface with mechanical durability was prepared on 6061 aluminum (Al) alloy by combining laser surface texturing (LST) and micro-arc oxidation (MAO) techniques followed by chemical immersion treatment. The effects of processing on Al alloys with different texturing spacings on the surface morphology, roughness, surface wettability, and corrosion resistance of the subsequently formed composite coatings were analyzed. The results show that a superhydrophobic surface was obtained with the water contract angle (WCA) of 158.3 ° and the roll-off angle of 9.5 ° at a texture spacing of 300 μm. This was due to the fact that the surface microroughness texturization process created by LST on the surface increased the generation of surface nanostructures, and combined with the natural nanostructure possessed by MAO, unique " double " nanostructure was formed on the surface. This surface structure increased the area of fluoride attachment, reduced the solid-liquid contact area, and decreased the adhesion of droplets to the surface, resulting in higher hydrophobicity. Electrochemical corrosion experiment showed that the corrosion current density of LM-300 was 2 orders of magnitude lower than that of the LM-0 sample, clearly demonstrating better corrosion resistance. In addition, the prepared superhydrophobic surface presented excellent mechanical durability, and in the ceramic zirconia cyclic abrasion experiment, the superhydrophobic surface was able to withstand 61 cycles of abrasion at a pressure of about 2.5 kPa.

Capacitive sensing of frost growth dynamics on aluminum surfaces with different wettabilities

Frost formation is a critical issue in many industries including air conditioning and refrigeration, aviation, transportation, and cryogenics. Frost buildup on heat exchanger surfaces reduces their efficiency by acting as a thermal resistance and by reducing or blocking the airflow. Defrosting is therefore necessary to maintain system efficiency. However, defrost initiation and cycle duration are critical parameters that govern system performance. Excessively early or late defrosting can result in energy loss. Frost detection is thus essential to carry out defrosting efficiently. To know when to initiate defrost, both the density and thickness of the frost must be known as both affect the frost thermal resistance. However, state of the art approaches are not sensitive to both frost density and thickness. Here, a capacitive sensing method is proposed that is sensitive to both the density and thickness of the frost. The method can achieve precise frost detection, offering insights into the ideal time to initiate defrosting by being sensitive to factors that affect frost specific thermal resistance. Experiments are carried out on plain (hydrophilic), superhydrophobic, and superhydrophilic aluminum surfaces at three different surface temperatures (−6 °C, −10 °C, −16 °C) to investigate the sensing performance. The capacitance measured increases with time as frost forms and grows. This change in capacitance, along with mass and thickness data, was used as a tool to characterize frost growth. The results indicate that decreasing wettability (superhydrophilic to plain (hydrophilic) to superhydrophobic) results in a decreasing trend in mass accumulation, frost density, and change in capacitance and an increasing trend in frost thicknesses and thermal resistance. It was also demonstrated that increasing surface temperature results in decreasing changes in capacitance (measurement sensitivity), mass accumulation, frost thicknesses, and thermal resistance, with an increasing trend in frost density. A strong correlation between frost mass and change in capacitance was observed regardless of surface temperature or wettability. This rendered implications for the best time of defrosting initiation. The proposed approach offers high accuracy, sensitivity, and convenience as a non-invasive method to study dynamic frost growth with insights into more optimal defrosting cycles, contributing to the development of more efficient energy systems.

Laser peening without coating fabricated superhydrophobic aluminum alloy with favorable mechanical properties

This study prepared 2024-T351 aluminum alloy surfaces with excellent hydrophobic properties by laser peening without coating(LPwC) and post-treatment process (silane solution immersion modification treatment). The surface morphology, microhardness, roughness and residual stress of the specimens before and after LPwC were characterized. Besides, the surface composition and droplet contact angle of the specimens before and after LPwC were measured to investigate the mechanism of enhancing the hydrophobic properties by LPwC. The results showed that after LPwC treatment, the surface of the specimen was uniformly distributed with a large number of micro-nano porous structures and the surface roughness was significantly increased. After the modification treatment with fluorosilane solution, the F element on the surface of the specimen significantly increased, the surface energy decreased, the droplet contact angle rose to above 150°, and the sliding angle dropped to below 10°, which imparted the superhydrophobicity on the surface. After LPwC treatment, the grain size of the specimen near-surface layer was reduced, and high magnitude residual compressive stress was generated inside the matrix, which increased the microhardness of material. The as-prepared superhydrophobic surface exhibits excellent water flow repellency and favorable mechanical properties, which promoted the application of superhydrophobic preparation process in the aerospace field.

Impact of gas bubbles on bacterial adhesion on super-hydrophobic aluminum surfaces

Super-hydrophobic surface (SHS), which traps micro/nano-scale gas bubbles on solid walls, has been reported to greatly reduce bacterial adhesion and biofouling. However, it is unclear whether and how the trapped gas bubbles reduce the bacterial adhesion. Here, we examine the role of the trapped gas on the bacterial adhesion by measuring the spatial distributions of attached bacteria on SHS using scanning electron microscopy (SEM). Two SHSs, one with regular micro-grooves, and the other with randomly roughed textures at micro/nano-scales, both created on aluminum substrates, were tested. We found that for a SHS where gas bubbles are trapped between roughness elements, bacteria only attach to the surface areas that are not covered by gas (e.g., top of roughness elements), while the areas covered by gas bubbles - gaps between roughness elements - are free of bacteria. In contrast, for a rough surface with the same texture geometry as that of SHS but no hydrophobic chemistry, bacteria are distributed evenly to the top and gap of roughness elements. Our results suggest that the SHS may reduce biofouling by providing a physical barrier of gas-liquid interface which separates bacteria from the solid walls. Furthermore, we showed that nano-scale roughness on SHS is insufficient to prevent bacterial adhesion. Our results should provide useful guidance for the future engineering design of efficient anti-biofouling materials.

Fabrication of superhydrophobic aluminum with enhanced anticorrosive property

The current work mainly introduces a facile method to obtain superhydrophobic aluminum with a hierarchical micro-nanostructure by a combination strategy of anodizing, chemical etching, and surface modification using SiO2@PDMS coating via a simple chemical vapor deposition (CVD) method. Scanning electron microscopy (SEM), energy dispersive X-ray (EDS), EDS-mapping, X-ray diffraction (XRD) and water contact angle (WCA) measurements have been performed to characterize the surface morphology, chemical composition, phase structure, and wetting property of the surfaces, respectively. The SEM results showed that by anodizing a network of cylindrical nanoporous is formed. By etching, the diameter of these pores increases and surface modification using CVD causes the deposition of SiO2@PDMS nanoparticles over them. The WCA measurements showed that the samples of the anodized and anodized-etched aluminum after modifying with SiO2@PDMS nanoparticles become superhydrophobic with values of 153° and 154°, respectively. The corrosion resistance of samples was analyzed by electrochemical impedance spectroscopy (EIS) and potentiodynamic polarization techniques. The results displayed that the charge transfer resistance of the superhydrophobic surface of modified anodized-etched aluminum is 16700 kΩ cm2, which is 900 times higher than that of pure aluminum. Also, the positive shift of 0.385 V in corrosion potential and reduction of more than 3 orders of magnitude in corrosion current are observed compared with aluminum. All results show a significant improvement in the corrosion protection of Al due to anodizing and surface modification with superhydrophobic coating. This method is suggested as a simple technique to creating aluminum with superhydrophobic surfaces in industry.

A composite pore-structured superhydrophobic aluminum surface for durable anti-icing

The icing of overhead aluminum conductors is a serious threat to the safe operation of power systems. Various coatings for anti-icing have to face the challenge of durability. Superhydrophobic (SHP) coatings with self-healing properties are gradually showing good anti-icing durability. Herein, SHP self-healing surfaces with composite pore structures were successfully constructed on 1060 aluminum by two-step anodizing and infusion of triethoxy (1H,1H,2H, 2H-perfluoro-1-octyl)silane (POTS). A preparation process of composite pore structure consisting of upper layer of large pores and lower layer of small pores was designed and obtained via two-step anodizing. The impregnated POTS modified the composite pore structure to achieve superhydrophobicity while providing self-healing properties. The SHP surfaces with excellent performance were prepared by optimizing the appropriate current density and oxidation time. The contact and sliding angles were 166.5° and 0.5°, respectively. The frosting time was extended to 175 min, whereas the ice adhesion strength was lowered to 4.3 kPa. Additionally, the SHP surface with composite pore structure demonstrated superior durability and self-healing properties to single pore structure. The composite pore structure could maintain outstanding superhydrophobicity after 12 times of damage/self-healing compared to single pore structure (eight times). The SHP surface with composite pore structure successfully self-healed three times and withstood 135 icing/deicing cycles keeping the ice adhesion strength below 20 kPa, which is preferable to single pore structure (two times). The SHP self-healing aluminum surfaces developed in this work are highly promising for application and can promote the development of SHP coatings for anti-icing on power transmission lines.

Preparation of a Wear-Resistant, Superhydrophobic SiO2/Polymethyl Methacrylate Composite Coating on Aluminum Surface Processed with Nanosecond Laser.

Superhydrophobic coatings are limited by complex preparation processes and poor mechanical durability in practical applications. In this study, a mechanically robust superhydrophobic composite coating was applied to an aluminum surface that underwent processing with a nanosecond laser (referred to as a superhydrophobic aluminum surface). It exhibits a high water contact angle (WCA) of 158.81°, a low sliding angle (SA) of less than 5°, and excellent self-cleaning ability. The wear test shows its durability, and the corrosion test shows its excellent corrosion resistance. This study provides a framework for the preparation of robust superhydrophobic surfaces that may have potential applications in many fields.

A hybrid substrate for practical applications in dropwise condensation enhancement

We introduce a durable hybrid substrate consisting of superhydrophilic micropillars surrounded by superhydrophobic depressions for practical industrial applications. The proposed surface can be mass-produced via a facile and affordable method. Moreover, the stability tests show that the wettability properties of fabricated surfaces do not vary after the imposition of hot steam flow for 110 h. Two hybrid samples with different patterns of micropillars are compared with superhydrophobic and bare aluminum samples to explore the physics behind the condensation improvement ability of hybrid surfaces. The results reveal that the heat transfer coefficient and heat flux can be significantly increased with the incorporation of micropillars with optimized dimensions. Among the tested surfaces, the hybrid one, whose pillar's diameters are 500 μm, increases the heat transfer coefficient by 33.50% and 19.60% with respect to the superhydrophobic and bare surfaces, respectively, at a subcooling temperature of 18.50 °C.

Metal dopant infused superhydrophobic aluminum surface through sustainable processing

The present work proposes a simple, scalable, and economical route for producing superhydrophobic surfaces using thermomechanical and microwave-assisted hydrothermal treatments. Infusing dopants (Mg, Fe) during thermomechanical processing resulted in a distinct and denser nanostructures on aluminum surface. The silanization of these surfaces resulted in superhydrophobicity (θa > 160°) with low hysteresis (≈ 2°) and adhesion (≈ 25 µN) compared to un-doped surface. The reduction in pitch between nanostructures enhanced capillary pressure (> 900 kPa), stabilizing Cassie state and restricting three-phase line sagging. The present work highlights the importance of doping in enhancing the durability of nanostructures for improving de-wettability.

Superhydrophobic aluminum surfaces with nano-micro hierarchical composite structures: A novel and sustainable approach to corrosion protection

The unique properties of aluminum (Al) and its alloys make Al one of the most versatile, economical, and widely-used materials in various industries. However, the corrosion and leaching of Al can cause significant issues for the lifetimes of mechanical structures and machine components as well as environment and health problems. In the present study, a simple, eco-friendly, and rapid fabrication of superhydrophobic Al surfaces was introduced. The superhydrophobic Al surfaces with hierarchical composite structures combining microstructures prepared by laser texturing, the new formation of pseudo-boehmite nanostructures prepared by boiling water treatment, and low surface energy prepared by silicone oil heat treatment showed excellent corrosion resistance. The mechanism for wettability change and anti-corrosion were analyzed. The influence of laser parameters and surface modification procedures on the wettability and corrosion resistance of Al surfaces was also analyzed systematically through a series of surface characterization techniques, potentiodynamic polarization tests, and electrochemical impedance spectroscopy tests. The corrosion protection efficiency of the fabricated superhydrophobic Al surface has reached up to 99.40 % as compared with an untreated flat surface. Furthermore, the fabricated superhydrophobic surfaces show good stability even after prolonged exposure to air, fresh water, seawater, and high temperature environments. The performance of the non-wetting surfaces is demonstrated through self-cleaning, water jetting, and water droplet bouncing phenomena. This research provides a novel and sustainable approach for superhydrophobic metal surfaces and improved corrosion resistance for potential practical applications.

Fabrication of wear-resistant and superhydrophobic aluminum alloy surface by laser-chemical hybrid methods

To achieve rapid, efficient, and low-cost preparation of large-scale stable aluminum alloy superhydrophobic surfaces, a new preparation method is proposed. The outer surface of the array micro-protrusions was coated with a layer of armor, which was the molten spatter produced during picosecond laser processing. The molten sputters and micro-protrusions combined to form micro–nano composite multi-layer structures. Through these special array micro–nano composite multi-layer structures and chemical modification, the wear-resistant and superhydrophobic properties of aluminum alloy surfaces were realized. According to test results, the array micro–nano composite structures prepared by picosecond laser and chemical modification had a water drop contact angle of 154.6° and a water drop rolling angle of 2°, exhibiting excellent superhydrophobic and anti-adhesion properties. Its self-cleaning, corrosion resistance and friction and wear behavior were systematically analyzed. The analysis results showed that the rolling droplets on the prepared surface could easily take away contaminants. The corrosion voltage and corrosion current density of the prepared superhydrophobic surface are significantly lower than that of the raw surface. In addition, a water drop contact angle of the aluminum alloy sample maintained at 145.1° after five wear tests, indicating the prepared surface after wear testing still had hydrophobic performance. The innovative method proposed in this study provides a simple and effective method for preparing large-scale wear-resistant superhydrophobic surface of aluminum alloy.