Durability and Wear Resistance of Laser-Textured Hardened Stainless Steel Surfaces with Hydrophobic Properties

Adhesive Joints with Laser Shaped Surface Microstructures

One of the most commonly applied methods of joining dissimilar materials is gluing. This could be mainly attributed to the applicability of this technique in various industries. The article presents a method of material surface treatment, which increases the shear strength of adhesive joints for lightweight metals such as aluminum with plastics. For this purpose, laser surface microstructuring was performed on each of the selected construction materials. As a result of the performed treatment, the active surface of the glued area was increased, which increased the adhesive strength. The picosecond laser with UV radiation used in the research is TruMicro 5325c with which material can be removed as a result of the cold ablation phenomenon. The applied parameters of the laser device did not cause thermal damage to the surface of the microstructured materials, which was confirmed by microscopic examination. Laser micromachining did not deteriorate the degree of wetting of the tested materials, either, as was confirmed by the contact angle and surface energy measurements with the use of water as the measuring liquid. In investigated cases of microstructure types, the presented method significantly increased the shear strength of the joints formed, as demonstrated by the presented strength test results. Research has shown that created joints with microstructure made according to the described method, are characterized by a significant increase in strength, up to 376%, compared to materials without microstructure. The presented results are part of a series of tests aimed at selecting the operating laser parameters for the implementation of geometric shapes of microstructures which will increase the strength of adhesive joints in selected materials.

Effects of Surface Morphology on Erosion–Corrosion and Corrosion Resistance of Highly Hydrophobic Nickel-Tungsten Electrodeposited Film

Hard nanocrystalline Ni-Co or Ni-W coatings are receiving a growing interest owing to their premium hardness, wear, and corrosion properties for several industrial applications. Furthermore, surface hydrophobicity greatly improves surface corrosion resistance. In this research, the durability of hydrophobic hierarchical NiW electrodeposited film has been evaluated in a high-speed slurry erosion–corrosion (EC) test rig. Two different coatings have been tested: a rough coating obtained in a chloride-based bath (NiWchloride) and a smooth coating obtained in a sulfate-based bath (NiWsulfate). Corrosion behavior over time was evaluated by electrochemical impedance spectroscopy (EIS), while surface hydrophobic performance was determined by the sessile drop method. The morphological features of the coatings were assessed by scanning electron microscopy while roughness modification during the EC tests were identified by means of an atomic force microscopy. During static immersion in the aggressive solution, the impedance modulus of the coatings continuously increased due to an increase in the thickness of corrosion products. During the EC test, the impedance modulus of the smooth NiW coating decreased, losing its barrier property. It was observed that the increase in impedance modulus of the hierarchical structure of the rough NiW coating during EC was far greater than that during static immersion. After 64 min of EC, the NiWchloride was able to resume its hydrophobicity property by storing in air; nevertheless, the NiWsulfate, with a loss of approximately 72% in its initial contact angle, was no longer hydrophobic. The results showed improvements in the lifetime of hydrophobic NiW coatings in erosion–corrosion conditions of the hierarchical nanostructure obtained in a chloride-based electroplating bath.

Recent Progress on Wear-Resistant Materials: Designs, Properties, and Applications

There has been tremendous interest in the development of different innovative wear-resistant materials, which can help to reduce energy losses resulted from friction and wear by ≈40% over the next 10-15 years. This paper provides a comprehensive review of the recent progress on designs, properties, and applications of wear-resistant materials, starting with an introduction of various advanced technologies for the fabrication of wear-resistant materials and anti-wear structures with their wear mechanisms. Typical strategies of surface engineering and matrix strengthening for the development of wear-resistant materials are then analyzed, focusing on the development of coatings, surface texturing, surface hardening, architecture, and the exploration of matrix compositions, microstructures, and reinforcements. Afterward, the relationship between the wear resistance of a material and its intrinsic properties including hardness, stiffness, strength, and cyclic plasticity is discussed with underlying mechanisms, such as the lattice distortion effect, bonding strength effect, grain size effect, precipitation effect, grain boundary effect, dislocation or twinning effect. A wide range of fundamental applications, specifically in aerospace components, automobile parts, wind turbines, micro-/nano-electromechanical systems, atomic force microscopes, and biomedical devices are highlighted. This review is concluded with prospects on challenges and future directions in this critical field.

Porosity-induced mechanically robust superhydrophobicity by the sintering and silanization of hydrophilic porous diatomaceous earth

HYPOTHESIS

Because they have self-similar low-surface-energy microstructures throughout the whole material block, fabricating superhydrophobic monoliths has been currently a promising remedy for the mechanical robustness of non-wetting properties. Noticeably, porous materials have microstructured interfaces throughout the complete volume, and silanization can make surfaces low-surface-energy. Therefore, the porous structure and surface silane-treatment can be combined to render hydrophilic inorganics into mechanically durable superhydrophobic monoliths.

EXPERIMENTS

Superhydrophobic diatomaceous earth pellets were produced by thermal-sintering, followed by a silanization process with octyltriethoxysilane. The durability of superhydrophobicity was evaluated by changes in wetting properties, surface morphology, and chemistry after a systematic abrasion sliding test.

FINDINGS

The intrinsic porosity of diatomite facilitated surface silanization throughout the whole sintered pellet, thus producing the water-repelling monolith. The abrasion sliding converted multimodal porosity of the volume to hierarchical roughness of the surface comprised of silanized particles, thereby attaining superhydrophobic properties of high contact angles over 150° and sliding angles below 20°. The tribological properties revealed useful information about the superhydrophobicity duration of the non-wetting monolith against friction. The result enables the application of porous structures in the fabrication of the anti-abrasion superhydrophobic materials even though they are originally hydrophilic.

Icephobic Performance of Multi-Scale Laser-Textured Aluminum Surfaces for Aeronautic Applications

Ice-building up on the leading edge of wings and other surfaces exposed to icing atmospheric conditions can negatively influence the aerodynamic performances of aircrafts. In the past, research activities focused on understanding icing phenomena and finding effective countermeasures. Efforts have been dedicated to creating coatings capable of reducing the adhesion strength of ice to a surface. Nevertheless, coatings still lack functional stability, and their application can be harmful to health and the environment. Pulsed laser surface treatments have been proven as a viable technology to induce icephobicity on metallic surfaces. However, a study aimed to find the most effective microstructures for reducing ice adhesion still needs to be carried out. This study investigates the variation of the ice adhesion strength of micro-textured aluminum surfaces treated using laser-based methods. The icephobic performance is tested in an icing wind tunnel, simulating realistic icing conditions. Finally, it is shown that optimum surface textures lead to a reduction of the ice adhesion strength from originally 57 kPa down to 6 kPa, corresponding to a relative reduction of ~90%. Consequently, these new insights will be of great importance in the development of functionalized surfaces, permitting an innovative approach to prevent the icing of aluminum components.

Thermally Induced Gradient of Properties on a Superhydrophobic Magnesium Alloy Surface

Fabrication of superhydrophobic coatings for magnesium alloys is in high demand for various industrial applications. Such coatings not only extend the service life of metal structures, but also impart additional useful functional properties to the coated surface. In this study, we show that nanosecond laser processing of long, thin stripes of magnesium alloys followed by the deposition of a hydrophobic agent onto the magnesium oxide layer is a simple, convenient, and easily reproducible method for obtaining superhydrophobic surfaces with property gradient along the sample. The mechanism of the gradient in wettability and electrochemical properties of the magnesium alloy surface is discussed based on the high-temperature growth of magnesium oxide and its following degradation. The latter is related to the development of internal stresses and the formation of cracks and pores within the oxide layer at prolonged exposure to high temperatures during the interaction of a laser beam with the substrate. The effect of heating during laser processing of magnesium materials with limited sizes on the protective properties of the forming coatings is elucidated.

Anti-Biofouling Properties of Femtosecond Laser-Induced Submicron Topographies on Elastomeric Surfaces

Antibacterial coatings are often employed to elastomer surfaces to inhibit bacterial attachment. However, such approaches could lead to increased antibiotic resistance. Surface micro-/nanotexturing is gaining significant attention recently, as it is a passive approach to reduce bacterial adhesion to surfaces. To this end, this work aims to assess the anti-biofouling functionality of femtosecond laser-induced submicron topographies on biomedical elastomer surfaces. Femtosecond laser processing was employed to produce two types of topographies on stainless-steel substrates. The first one was highly regular and single scale submicron laser-induced periodic surface structures (LIPSS) while the second one was multiscale structures (MSs) containing both submicron- and micron-scale features. Subsequently, these topographies were replicated on polydimethylsiloxane (PDMS) and polyurethane (PU) elastomers to evaluate their bacterial retention characteristics. The submicron textured PDMS and PU surfaces exhibited long-term hydrophobic durability up to 100 h under immersed conditions. Both LIPSS and MS topographies on PDMS and PU elastomeric surfaces were shown to substantially reduce (>89%) the adhesion of Gram-negative Escherichia coli bacteria. At the same time, the anti-biofouling performance of LIPSS and MS topographies was found to be comparable with that of lubricant-impregnated surfaces. The influence of physical defects on textured surfaces on the adhesion behavior of bacteria was also elucidated. The results presented here are significant because the polymeric biomedical components that can be produced by replication cost effectively, while their biocompatibility can be improved through femtosecond surface modification of the respective replication masters.

Design of Chemical Surface Treatment for Laser-Textured Metal Alloys to Achieve Extreme Wetting Behavior

Extreme wetting activities of laser-textured metal alloys have received significant interest due to their superior performance in a wide range of commercial applications and fundamental research studies. Fundamentally, extreme wettability of structured metal alloys depends on both the surface structure and surface chemistry. However, compared with the generation of physical topology on the surface, the role of surface chemistry is less explored for the laser texturing processes of metal alloys to tune the wettability. This work introduces a systematic design approach to modify the surface chemistry of laser textured metal alloys to achieve various extreme wettabilities, including superhydrophobicity/superoleophobicity, superhydrophilicity/superoleophilicity, and coexistence of superoleophobicity and superhydrophilicity. Microscale trenches are first created on the aluminum alloy 6061 surfaces by nanosecond pulse laser surface texturing. Subsequently, the textured surface is immersion-treated in several chemical solutions to attach target functional groups on the surface to achieve the final extreme wettability. Anchoring fluorinated groups (-CF₂- and -CF₃) with very low dispersive and nondispersive surface energy leads to superoleophobicity and superhydrophobicity, resulting in repelling both water and diiodomethane. Attachment of the polar nitrile (-C≡N) group with very high nondispersive and high dispersive surface energy achieves superhydrophilicity and superoleophilicity by drawing water and diiodomethane molecules in the laser-textured capillaries. At last, anchoring fluorinated groups (-CF₂- and -CF₃) and polar sodium carboxylate (-COONa) together leads to very low dispersive and very high nondispersive surface energy components. It results in the coexistence of superoleophobicity and superhydrophilicity, where the treated surface attracts water but repels diiodomethane.

Ultrafast Laser Enabling Hierarchical Structures for Versatile Superhydrophobicity with Enhanced Cassie-Baxter Stability and Durability

The controllable and facile fabrication of surface micro/nanostructures with the required dimensions and morphologies is the key to achieving surface superhydrophobicity. With the advantages of being a noncontact, maskless, programmable, and one-step process, ultrafast laser irradiation is a very flexible and adaptive technique for fabricating various microscale, nanoscale, and micro/nanomultiscale surface structures on diverse solids, thus realizing superhydrophobicity on their surfaces. In this feature article, a comprehensive review of our recent research advances on versatile superhydrophobic surfaces enabled by ultrafast lasers is presented from the perspectives of materials, methodologies, and functionalization. The realization of superhydrophobicity and even superamphiphobicity on varied solid surfaces through ultrafast laser treatment and the underlying mechanisms for the wettability transition of ultrafast-laser-processed surfaces from superhydrophilicity to superhydrophobicity will be discussed. For the sake of practical applications, the ultrafast-laser-based strategies for the large-scale and cost-effective fabrication of superhydrophobic surface micro/nanostructures will be introduced. A special focus will be devoted to the enhancement of structural durability and the Cassie-Baxter stability of ultrafast-laser-enabled superhydrophobic surfaces. Beyond that, the achievement of integrated surface functions including remarkable wetting functions such as the directional collection of water droplets and superhydrophobic surfaces simultaneously with unique optical properties will also be presented.