Superhydrophobic Films with Enhanced Corrosion Resistance and Self-Cleaning Performance on an Al Alloy

Dense Amorphous Passivation Layer Formed on Aluminum Alloy Surfaces by Femtosecond Laser-Assisted Oxygen-Rich Doping

Aluminum (Al) alloy surfaces are prone to serious corrosion in humid and salt-laden environments, which promotes the development of numerous protective approaches. Although the amorphous state is more conducive to improve corrosion resistance compared with the crystalline state, it still faces coating design problems like insufficient adhesive strength and flaking-off tendency. Here, we propose a strategy of femtosecond laser-assisted oxygen-rich doping to in situ create a dense high-quality passivation layer on Al alloy surfaces. With respect to the femtosecond laser processing in traditional air ambience, the material surface modifications within the oxygen-rich environment demonstrate some distinctiveness. For the ridge area of the laser ablation grooves, the oxidation surface is separated into two layers: the outer region presents a loose and porous appearance similar to the observations in the air ambience, while the inner region exhibits complete and homogeneous oxidation, especially associated with the continuous distribution of the amorphous substance, in sharp contrast to the nanoscale discrete amorphous formation in the air case. Simultaneously, the high degree of material oxidization with the amorphous phase is also developed on the wallside area of the groove valleys, which is much different from the incomplete oxidation in the air ambience. As a result, the measured corrosion current decreases by 49 times to a value of Icorr = 1.19 × 10-10 A/cm2 relative to the laser treatment in the air environment. Such a method offers the prospect for elevating the anticorrosion performance of metal surfaces.

A comprehensive review on anticorrosive/antifouling superhydrophobic coatings: Fabrication, assessment, applications, challenges and future perspectives

Superhydrophobicity (SHP) is an incredible phenomenon of extreme water repellency of surfaces ubiquitous in nature (E.g. lotus leaves, butterfly wings, taro leaves, mosquito eyes, water-strider legs, etc). Historically, surface exhibiting water contact angle (WCA) > 150° and contact angle hysteresis <10° is considered as SHP. The SHP surfaces garnered considerable attention in recent years due to their applications in anti-corrosion, anti-fouling, self-cleaning, oil-water separation, viscous drag reduction, anti-icing, etc. As corrosion and marine biofouling are global problems, there has been focused efforts in combating these issues using innovative environmentally friendly coatings designs taking cues from natural SHP surfaces. Over the last two decades, though significant progress has been made on the fabrication of various SHP surfaces, the practical adaptation of these surfaces for various applications is hampered, mainly because of the high cost, non-scalability, lack of simplicity, non-adaptability for a wide range of substrates, poor mechanical robustness and chemical inertness. Despite the extensive research, the exact mechanism of corrosion/anti-fouling of such coatings also remains elusive. The current focus of research in recent years has been on the development of facile, eco-friendly, cost-effective, mechanically robust chemically inert, and scalable methods to prepare durable SHP coating on a variety of surfaces. Although there are some general reviews on SHP surfaces, there is no comprehensive review focusing on SHP on metallic and alloy surfaces with corrosion-resistant and antifouling properties. This review is aimed at filling this gap. This review provides a pedagogical description with the necessary background, key concepts, genesis, classical models of superhydrophobicity, rational design of SHP, coatings characterization, testing approaches, mechanisms, and novel fabrication approaches currently being explored for anticorrosion and antifouling, both from a fundamental and practical perspective. The review also provides a summary of important experimental studies with key findings, and detailed descriptions of the evaluation of surface morphologies, chemical properties, mechanical, chemical, corrosion, and antifouling properties. The recent developments in the fabrication of SHP -Cr-Mo steel, Ti, and Al are presented, along with the latest understanding of the mechanism of anticorrosion and antifouling properties of the coating also discussed. In addition, different promising applications of SHP surfaces in diverse disciplines are discussed. The last part of the review highlights the challenges and future directions. The review is an ideal material for researchers practicing in the field of coatings and also serves as an excellent reference for freshers who intend to begin research on this topic.

Ultrathin Water-Responsive Zwitterionic Hydrogel Brush Coatings for Long-Term Corrosion Protection

Preventing metal corrosion has usually been associated with water-repellent coatings that inhibit the penetration of aggressive chloride ions. Contrary to this conventional wisdom, we engineered ultrathin superhydrophilic zwitterionic hydrogel brushes rooted in a nanoporous anodic aluminum oxide (AAO) substrate that effectively hampered the adsorption of hydrated chloride ions (Cl-·H2O) on the Al alloy surface. The hydrogel brush coating enhanced corrosion resistance by 3 orders of magnitude, with corrosion current density declining from 1.518 to 1.567 × 10-3 μA cm-2. Despite suffering from long-term salt-spaying tests, zwitterionic hydrogel brush coating retained 2 orders of magnitude of corrosion resistance. Direct Raman spectroscopic evidence manifested that interfacial water comprised both highly ordered hydrogen-bonded water and disordered water containing hydrated Cl- ions. Under the hydration effect of zwitterionic hydrogel brushes, an interfacial disordered water structure dynamically transformed into a hydrogen-bonded water film. We correlated the structure and quantities of interfacial water with the corrosion current density and chloride adsorption. Hydrogen-bonded water improved by zwitterionic hydrogel brushes weakened the affinity and adsorption of hydrated Cl- ion water on the oxide film, resulting in excellent corrosion protection. Therefore, employing localized hydration tuning strategies, these findings are anticipated to generally empower ordered interfacial water to enhance metal corrosion resistance through precise interfacial engineering.

Chemical Etching, Thermally Driven Combination Strategy to Fabricate Superhydrophobic Fe-Based Amorphous Coatings with Excellent Anticorrosion Property: Based on Hydroxylation Effect

Fe-based amorphous coatings are ideal materials for surface protection due to their outstanding mechanical properties and corrosion resistance. However, coating defects are inevitably formed during the preparation of coatings by thermal spray technology, which seriously affects the corrosion performance. Inspired by bionics, conceiving superhydrophobic surfaces with liquid barrier properties has become a new idea for the corrosion protection of metal surfaces. In this work, based on surface hydroxylation, we designed a superhydrophobic Fe-based amorphous coating with corrosion resistance by chemical etching combined with a thermally driven preparation strategy. The obtained superhydrophobic coatings exhibit liquid repellency (contact angle >150°) and excellent corrosion resistance (corrosion current density and passive current density reduced by 3 orders of magnitude). The results revealed that the superhydrophobic behavior stems from the construction of hydroxyl-induced surface micro-/nanomultilevel aggregates (cluster structures). The hydrophobic agent layer deposited on the surface of cluster aggregates and the nanoparticle elements that constitute the clusters dominate the corrosion resistance of the coating. This work provides an effective guide to the design of high-corrosion-resistant Fe-based amorphous alloy coatings and promotes their engineering applications.

Recent Advances in Fabrication of Durable, Transparent, and Superhydrophobic Surfaces

Transparent superhydrophobic coatings have been extensively investigated due to their ability to provide self-cleaning properties for outdoor applications. However, the widespread implementation of these coatings on a large scale is impeded by the challenges of poor durability and complex fabrication procedures. In this review, the fundamentals and theories governing the mutually exclusive properties of superhydrophobicity, optical transparency, and susceptibility to wear are introduced, followed by a discussion of representative examples of advanced surface design and processing optimizations. Also, robust evaluation protocols for assessing mechanical and chemical stabilities are briefed and potential research directions are presented. This review can offer the research community a better understanding of durable and transparent superhydrophobic surfaces, thereby facilitating their development for real-world applications.

Fabrication of Robust, Anti-reflective, Transparent Superhydrophobic Coatings with a Micropatterned Multilayer Structure

Transparent superhydrophobic coatings with mechanical stability, self-cleaning function, and anti-reflective property have drawn much attention due to the great potential in a variety of real-world applications. In this work, we develop an ingenious approach to construct micropatterned transparent superhydrophobic coatings with a multilayer structure (water contact angle ∼153.6°, sliding angle ∼3.2°). A micropatterned ultraviolet-cured resist frame facilitates durability, while the modified silica nanoparticles, which are housed within the micro-cavities and bonded by an epoxy-based adhesive, impart superhydrophobicity. The micropatterned multilayer surface could endure sandpaper abrasion while maintaining satisfactory hydrophobicity. The prepared surfaces also retain the excellent water repellency after water jet impact, acid submerging, and mechanical bending, suggesting that they are sustainable in the case of adverse conditions and can be integrated with objects with non-flat geometries. Further, the superhydrophobic coatings exhibit an anti-reflection property while preserving high transparency. Taken together, we envision that the design strategies here can offer a practicable route to produce transparent superhydrophobic coatings for diverse outdoor applications.

Long-Term Static and Dynamic Corrosion Stability of Nonwetting Surfaces

Superhydrophobic surfaces (SHSs) and lubricant-infused surfaces (LISs) are two classes of nonwetting surfaces that have drawn attention due to their advanced functional properties including corrosion inhibition. Yet there is a conspicuous lack of corrosion study of SHSs and LISs with respect to their fabrication and material parameters, especially at high temperatures and under dynamic flow conditions over long durations, which is sought to be addressed in this article. Considering copper SHSs and LISs, a full factorial combinatorial study of two facile texturing processes, electrodeposition and etching, two different functionalization agents, stearic acid and mercaptan, and two types of infused lubricants, Krytox 104 and DOWSIL 510, is presented, encompassing over 650 measurements on 90 tested surfaces. All fabricated surfaces demonstrated water repellency with a contact angle above 150° and a sliding angle below 7°. For the first time, the study examines high-temperature corrosion stability and long-term corrosion durability of the nonwetting surfaces in both static fluid and dynamic turbulent flow conditions over a period of 30 days. LISs and SHSs are shown to provide excellent corrosion inhibition over all tested corrosion conditions, with negligible presence of corrosion species on the surfaces and no deterioration of the texturing. The surfaces are also shown to rejuvenate easily to the initial wettability and corrosion resistance values. This study provides valuable insights into the selection of materials and processing parameters for the fabrication of nonwetting surfaces for the application of interest.

Bioinspired nonwetting surfaces for corrosion inhibition over a range of temperature and corrosivity

Applications of superhydrophobic (SHS) and lubricant infused surfaces (LIS) involve exposure to corrosive environments from the acidic to the basic, at a range of temperatures, that are not fully characterized. We present for the first time a multifactorial study of the effects of surface fabrication method, surface modification, surface functionalization time, temperature and pH of the immersion medium on the corrosion performance of nonwetting copper surfaces. Bioinspired SHS and LIS fabricated using facile methods of etching and electrodeposition are systematically assessed using potentiodynamic polarization measurements for their corrosion resistance in saline solution (pH≈ 7) over a temperature range 23-85 °C. SHS and LIS are shown to exhibit diminished corrosion rate, by up to two orders of magnitude, compared to bare copper surface. An Arrhenius model is developed for the first time, describing the temperature-dependent corrosion rate of SHS and LIS. Electrochemical impedance spectroscopy is used to show that corrosion resistance of LIS is larger by three orders of magnitude in extremely acidic (pH = 1) and by an order magnitude in extremely alkaline (pH = 14) media compared to bare copper surface. Etched LIS are generally more resistant to corrosion compared to SHS at all temperatures with excellent microstructural durability.

Extended Gibbs Free Energy and Laplace Pressure of Ordered Hexagonal Close-Packed Spherical Particles: A Wettability Study

The wetting property of spherical particles in a hexagonal close-packed (HCP) ordering from extended Gibbs free energy (GFE) and Laplace pressure view points is studied. A formalism is proposed to predict the contact angle (θ) of a droplet on the HCP films and penetration angle (α) of the liquid on the spherical particles. Then, the extended Laplace pressure for the layered HCP ordering is calculated and a correlation between the wetting angle, sign of pressure, and pressure gradient is achieved. Our results show that the sign and the slope of pressure are important criteria for determining the wettability state and it is found that the contact angle is independent of the particle radius, as supported by various experimental reports. The pressure gradient for the HCP films with Young contact angle higher than (lower than) a critical contact angle, 135° (45°), is positive (negative), indicating the superhydrophobicity (superhydrophilicity) state of the surface. To validate the proposed formulation, theoretical calculations are compared with the reported experimental measurements, showing a good agreement.

Durable and Flexible Hydrophobic Surface with a Micropatterned Composite Metal-Polymer Structure

Hydrophobic metallic surfaces have attracted much academic and industrial interest due to their promising applications in various fields. Typically, hydrophobicity in metallic materials can be realized by micro/nanostructures and chemical treatment. However, both fragile rough surfaces and low-surface-energy fluorinated silanes are prone to wear and abrasion, leading to the loss of hydrophobicity. In this experiment, we demonstrated a facile and potentially low-cost methodology to fabricate hydrophobic surfaces by integrating a mechanically durable nickel skeleton with an interconnected microwall array filled with hydrophobic poly(tetrafluoroethylene) (PTFE). The interconnected metal frames prevented the removal of the hydrophobic material by abradants, and good hydrophobicity was preserved after more than 1000 cycles of linear abrasion under a local pressure of ∼0.12 MPa. The fabricated surfaces exhibited enhanced anti-icing properties with water droplets compared to unprocessed nickel surfaces. The prepared surfaces also showed superior flexibility. No obvious fracture was observed even after 300 cycles of buckling while the hydrophobic performance was still maintained. The surfaces designed here could provide effective guidance to manufacture large-area surfaces in nickel and other metallic materials that require flexibility, hydrophobic properties, and anti-icing functions for harsh applications.

Superhydrophobic and Antioxidative Film Based on Edible Materials for Food Packaging

Significant wastage of the food deterioration in the food preserving process and residual liquid in a container has become a major concern for scientists and the whole society. In this study, an edible multifunctional film integrated superhydrophobicity and antioxidant ability is constructed by chitosan, tea polyphenol, carnauba wax material that is food and drug administration (FDA)-approved for food packaging. The formed edible packaging materials that exhibit great antioxidant property and extremely low water-absorbing quality, was thus proven to display excellent fresh beef preservation effect during storage of 14 days. Importantly, the formed edible multifunctional interface was also demonstrated to perform excellent superhydrophobicity due to the carnauba wax and exhibited large contact angles for various liquid foods, which could effectively reduce the liquid residue. Moreover, the formed edible multifunctional packaging materials showed good thermostability and biocompatibility, which has the potential to be applied as a functional packaging material.

A Review of Fabrication Methods, Properties and Applications of Superhydrophobic Metals

Hydrophobicity and superhydrophobicity with self-cleaning properties are well-known characteristics of several natural surfaces, such as the leaves of the sacred lotus plant (Nelumbo nucifera). To achieve a superhydrophobic state, micro- and nanometer scale topography should be realized on a low surface energy material, or a low surface energy coating should be deposited on top of the micro-nano topography if the material is inherently hydrophilic. Tailoring the surface chemistry and topography to control the wetting properties between extreme wetting states enables a palette of functionalities, such as self-cleaning, antifogging, anti-biofouling etc. A variety of surface topographies have been realized in polymers, ceramics, and metals. Metallic surfaces are particularly important in several engineering applications (e.g., naval, aircrafts, buildings, automobile) and their transformation to superhydrophobic can provide additional functionalities, such as corrosion protection, drag reduction, and anti-icing properties. This review paper focuses on the recent advances on superhydrophobic metals and alloys which can be applicable in real life applications and aims to provide an overview of the most promising methods to achieve sustainable superhydrophobicity.

Fabrication of a micro/nanoscaled hierarchical structure surface on brass with anti-icing and self-cleaning properties

The micro/nanoscaled hierarchical structure could trap a large volume of air to form an “air-cushion”, which improves the anti-icing and self-cleaning properties.