Facile fabrication of superhydrophobic surfaces with hierarchical structures

Fabrication of Bulk Tungsten Microstructure Arrays for Hydrophobic Metallic Surfaces Using Inductively Coupled Plasma Deep Etching

Hydrophobic surfaces have attracted great attention due to their ability to repel water, and metallic surfaces are particularly significant as they have several benefits, for example they self-clean and do not corrode in marine environments, but also have several applications in the aircraft, building and automobile industries. Tungsten is an ideal material for metallic surfaces due to its remarkable mechanical properties. However, conventional micromachining methods of micro- or nanostructures, including mechanical fabrication and laser and wet etching are incapable of balancing functionality, consistency and cost. Inspired by the etching process of silicon, deep etching of bulk tungsten has been developed to achieve versatile microstructures with the advantages of high efficiency, large scale and low cost. In this article, fabrication methods of tungsten-based hydrophobic surfaces using an ICP deep etching process were proposed. Micro- or hierarchical structure arrays with controllable sidewall profiles were fabricated by optimizing etching parameters, which then exhibited hydrophobicity with contact angles of up to 131.8°.

Superhydrophobic Antifrosting 7075 Aluminum Alloy Surface with Stable Cassie-Baxter State Fabricated through Direct Laser Interference Lithography and Hydrothermal Treatment

Frost formation and accumulation can have catastrophic effects on a wide range of industrial activities. Hence, a dual-scale surface with a stable Cassie-Baxter state is developed to mitigate the frosting problem by utilizing direct laser interference lithography assisted with hydrothermal treatment. The high Laplace pressure tolerance under the evaporation stimulus and prolonged Cassie-Baxter state maintenance under the condensation stimulus demonstrate the stable Cassie-Baxter state. The dual-scale surface exhibits a lengthy frost-delaying time of up to 5277 s at -7 °C due to the stable Cassie-Baxter state. The self-removal of frost is achieved by promoting the mobility of frost melts driven by the released interfacial energy. In addition, the dense flocculent frost layer is observed on the single-scale micro surface, whereas the sparse pearl-shaped frost layer with many voids is obtained on the dual-scale surface. This work will aid in understanding the frosting process on various-scale superhydrophobic surfaces and in the design of antifrosting surfaces.

One-Step Fabrication of Hot-Water-Repellent Surfaces

Hot-water repellency is of great challenge on traditional superhydrophobic surfaces due to the condensation of tiny droplets within the cavities of surface textures, which builds liquid bridges to connect the substrate and hot water and thus destroys the surface water-repellence performance. For the unique structural features and scales, current approaches to fabricate surfaces with hot-water repellency are always complicated and modified by fluorocarbon. Here, we propose a facile and fluorine-free one-step vapor-deposition method for fabricating excellent hot-water-repellent surfaces, which at room temperature even repel water droplets of temperature up to 90 °C as well as other normal-temperature droplets with surface tension higher than 48.4 mN/m. We show that whether the unique hot-water repellency is achieved depends on a trade-off between the solid–liquid contact time and hot-vapor condensation time, which determines the probability of formation of liquid bridges between the substrate and hot-water. Moreover, the designed surfaces exhibit excellent self-cleaning performance in some specific situations, such as oil medium, hot water and condensation environments. We envision that this facile and fluorine-free strategy for fabricating excellent hot-water-repellent surfaces could be valuable in popularizing their practical applications.

Producing Fluorine- and Lubricant-Free Flexible Pathogen- and Blood-Repellent Surfaces Using Polysiloxane-Based Hierarchical Structures

High-touch surfaces are known to be a major route for the spread of pathogens in healthcare and public settings. Antimicrobial coatings have, therefore, garnered significant attention to help mitigate the transmission of infectious diseases via the surface route. Among antimicrobial coatings, pathogen-repellent surfaces provide unique advantages in terms of safety in public settings such as instant repellency, affordability, biocompatibility, and long-term stability. While there have been many advances in the fabrication of biorepellent surfaces in the past two decades, this area of research continues to suffer challenges in scalability, cost, compatibility with high-touch applications, and performance for pathogen repellency. These features are critical for high-touch surfaces to be used in public settings. Additionally, the environmental impact of manufacturing repellent surfaces remains a challenge, mainly due to the use of fluorinated coatings. Here, we present a flexible hierarchical coating with straightforward and cost-effective manufacturing without the use of fluorine or a lubricant. Hierarchical surfaces were prepared through the growth of polysiloxane nanostructures using n-propyltrichlorosilane (n-PTCS) on activated polyolefin (PO), followed by heat shrinking to induce microscale wrinkles. The developed coatings demonstrated repellency, with contact angles over 153° and sliding angles <1°. In assays mimicking touch, these hierarchical surfaces demonstrated a 97.5% reduction in transmission of Escherichia coli (E.coli), demonstrating their potential as antimicrobial coatings to mitigate the spread of infectious diseases. Additionally, the developed surfaces displayed a 93% reduction in blood staining after incubation with human whole blood, confirming repellent properties that reduce bacterial deposition.

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.

Fluorine-Free Transparent Superhydrophobic Nanocomposite Coatings from Mesoporous Silica

In recent decades, there has been a growing interest in the development of functional, fluorine-free superhydrophobic surfaces with improved adhesion for better applicability into real-world problems. Here, we compare two different methods, spin coating and aerosol-assisted chemical vapor deposition (AACVD), for the synthesis of transparent fluorine-free superhydrophobic coatings. The material was made from a nanocomposite of (3-aminopropyl)triethoxysilane (APTES) functional mesoporous silica nanoparticles and titanium cross-linked polydimethylsiloxane with particle concentrations between 9 to 50 wt %. The silane that was used to lower the surface energy consisted of a long hydrocarbon chain without fluorine groups to reduce the environmental impact of the composite coating. Both spin coating and AACVD resulted in the formation of superhydrophobic surfaces with advancing contact angles up to 168°, a hysteresis of 3°, and a transparency of 90% at 550 nm. AACVD has proven to produce more uniform coatings with concentrations as low as 9 wt %, reaching superhydrophobicity. The metal oxide cross-linking improves the adhesion of the coating to the glass. Overall, AACVD was the more optimal method to prepare superhydrophobic coatings compared to spin coating due to higher contact angles, adhesion, and scalability of the fabrication process.

Tunable Hierarchical Nanostructures on Micro-Conical Arrays of Laser Textured TC4 Substrate by Hydrothermal Treatment for Enhanced Anti-Icing Property

In this work, an anti-icing structured surface was fabricated by combining laser ablation with hydrothermal treatment. A micro-patterned surface on a Ti alloy (TC4) substrate was easily fabricated by a highly effective nanosecond pulsed laser ablation. It was observed that titania (TiO2) nanostructures were formed by hydrothermal treatment in aqueous alkali on the laser ablated TC4 substrate to obtain the micro/nano-hierarchical structures. The growth mechanism of the tunable nanoarrays was discussed by the adjustment of hydrothermal temperature. The as-prepared samples exhibited excellent superhydrophobicity with contact angles greater than 160°. It was found that optimized hydrothermal treatment on laser-processed TC4 substrates could further enhance surface anti-icing property. The results showed that the delay time (DT) had been extended by achieving over 90 min for the water droplets to freeze on the as-prepared structured surfaces, providing great potential in various anti-icing applications.