Rapid fabrication of anti-corrosion and self-healing superhydrophobic aluminum surfaces through environmentally friendly femtosecond laser processing

Wettability Behaviour of Metal Surfaces after Sequential Nanosecond and Picosecond Laser Texturing

This study examines the wettability behaviour of 304 stainless steel (304SS) and Ti-6Al-4V (Ti64) surfaces after sequential nanosecond (ns) and picosecond (ps) laser texturing; in particular, how the multi-scale surface structures created influence the lifecycle of surface hydrophobicity. The effect of different post-process treatments is also examined. Surfaces were analysed using Scanning Electron Microscopy (SEM), a white light interferometer optical profiler, and Energy Dispersive X-ray (EDX) spectroscopy. Wettability was assessed through sessile drop contact angle (CA) measurements, conducted at regular intervals over periods of up to 12 months, while EDX scans monitored elemental chemical changes. The results show that sequential (ns + ps) laser processing produced multi-scale surface texture with laser-induced periodic surface structures (LIPSS). Compared to the ns laser case, the (ns + ps) laser processed surfaces transitioned more rapidly to a hydrophobic state and maintained this property for much longer, especially when the single post-process treatment was ultrasonic cleaning. Some interesting features in CA development over these extended timescales are revealed. For 304SS, hydrophobicity was reached in 1-2 days, with the CA then remaining in the range of 120 to 140° for up to 180 days; whereas the ns laser-processed surfaces took longer to reach hydrophobicity and only maintained the condition for up to 30 days. Similar results were found for the case of Ti64. The findings show that such multi-scale structured metal surfaces can offer relatively stable hydrophobic properties, the lifetime of which can be extended significantly through the appropriate selection of laser process parameters and post-process treatment. The addition of LIPSS appears to help extend the longevity of the hydrophobic property. In seeking to identify other factors influencing wettability, from our EDX results, we observed a significant and steady rate of increase in the carbon content at the surface over the study period.

Development of a Superhydrophobic Protection Mechanism and Coating Materials for Cement Concrete Surfaces

In order to further enhance the erosion resistance of cement concrete pavement materials, this study constructed an apparent rough hydrophobic structure layer by spraying a micro-nano substrate coating on the surface layer of the cement concrete pavement. This was followed by a secondary spray of a hydroxy-silicone oil-modified epoxy resin and a low surface energy-modified substance paste, which combine to form a superhydrophobic coating. The hydrophobic mechanism of the coating was then analysed. Firstly, the effects of different types and ratios of micro-nano substrates on the apparent morphology and hydrophobic performance of the rough structure layer were explored through contact angle testing and scanning electron microscopy (SEM). Subsequently, Fourier transform infrared spectroscopy and permeation gel chromatography were employed to ascertain the optimal modification ratio, temperature, and reaction mechanism of hydroxy-silicone oil with E51 type epoxy resin. Additionally, the mechanical properties of the modified epoxy resin-low surface energy-modified substance paste were evaluated through tensile tests. Finally, the erosion resistance of the superhydrophobic coating was tested under a range of conditions, including acidic, alkaline, de-icer, UV ageing, freeze-thaw cycles and wet wheel wear. The results demonstrate that relying solely on the rough structure of the concrete surface makes it challenging to achieve superhydrophobic performance. A rough structure layer constructed with diamond micropowder and hydrophobic nano-silica is less prone to cracking and can form more "air chamber" structures on the surface, with better wear resistance and hydrophobic performance. The ring-opening reaction products that occur during the preparation of modified epoxy resin will severely affect its mechanical strength after curing. Controlling the reaction temperature and reactant ratio can effectively push the modification reaction of epoxy resin through dehydration condensation, which produces more grafted polymer. It is noteworthy that the grafted polymer content is positively correlated with the hydrophobicity of the modified epoxy resin. The superhydrophobic coating exhibited enhanced erosion resistance (based on hydrochloric acid), UV ageing resistance, abrasion resistance, and freeze-thaw damage resistance to de-icers by 19.41%, 18.36%, 43.17% and 87.47%, respectively, in comparison to the conventional silane-based surface treatment.

Laser-Assisted Structures for Efficient Fluid Management on Stainless Steel Surfaces

The article presents a high-productivity laser-structuring method combined with a hydrophobic post-treatment to create zone-structured surfaces with a decreasing wetting angle on AISI 304 stainless steel surfaces. We have investigated the impact of laser processing modes and hydrophobic substances on wetting and hysteresis angles and successfully demonstrated autonomous droplet movement over this zone-structured surface. A critical condition for autonomous fluid flow is the need for the drop to touch the boundary between the two zones. This can be achieved by settling the droplet directly on the boundary of the two zones or by using droplets whose surface contact diameter is on the order of magnitude or higher than the zone size. The zone-structured surface showed reusability, maintaining its properties even after 30 droplet passages. The zone-structured surfaces with a decreasing wetting angle can be used for moving a droplet along a complex trajectory as well as for mixing various liquids.

Superwettable surfaces and factors impacting microbial adherence in microbiologically-influenced corrosion: a review

Microbiologically-influenced corrosion (MIC) is a common operational hazard to many industrial processes. The focus of this review lies on microbial corrosion in the maritime industry. Microbial metal attachment and colonization are the critical steps in MIC initiation. We have outlined the crucial factors influencing corrosion caused by microorganism sulfate-reducing bacteria (SRB), where its adherence on the metal surface leads to Direct Electron Transfer (DET)-MIC. This review thus aims to summarize the recent progress and the lacunae in mitigation of MIC. We further highlight the susceptibility of stainless steel grades to SRB pitting corrosion and have included recent developments in understanding the quorum sensing mechanisms in SRB, which governs the proliferation process of the microbial community. There is a paucity of literature on the utilization of anti-quorum sensing molecules against SRB, indicating that the area of study is in its nascent stage of development. Furthermore, microbial adherence to metal is significantly impacted by surface chemistry and topography. Thus, we have reviewed the application of super wettable surfaces such as superhydrophobic, superhydrophilic, and slippery liquid-infused porous surfaces as "anti-corrosion coatings" in preventing adhesion of SRB, providing a potential avenue for the development of practical and feasible solutions in the prevention of MIC. The emerging field of super wettable surfaces holds significant potential for advancing efficient and practical MIC prevention techniques.

Microscopic mechanisms for initiation and evolution of femtosecond laser-induced columnar structures above the surface level of aluminum

A better understanding of the formation of femtosecond (fs) laser-induced surface structures is key to the control of their morphological profiles for desired surface functionalities on metals. In this work, with fs laser pulse irradiation, the two stages of formation mechanisms of the columnar structures (CSs) grown above the surface level are investigated on pure Al plates in ambient air. Here, we find that the redeposition of ablated microscale clusters following fs laser pulses of irradiation acts as the nucleation sites of CS formation, which strongly affects their location and density within the laser spot. Furthermore, we suggest their structural growths and morphological shape changes are directly associated with the competition among four laser-impact hydrodynamical phenomena: laser ablation, subsequent molten metal flow, particles' redeposition, and metal vapor condensation with continued pulse irradiation.

Owens-Wendt Method for Comparing the UV Stability of Spontaneous Liquid-Repellency with Wet Chemical Treatment of Laser-Textured Stainless Steel

The liquid-repellent properties of AISI 304 stainless steel surfaces textured with a femtosecond laser were studied, both after spontaneous hydrophobization and when treated with stearic acid and octyltrimethoxysilane. Surface topography has been shown to play a critical role in determining these properties. Although textures containing only LIPSS exhibited poor liquid-repellency, the performance was significantly improved after engraving the microtexture. The most effective topography consisted of 45 µm-wide grooves with a pitch of 60 µm and protrusions covered with a rough microcrystalline structure. Liquid-repellency, chemical treatment efficiency, and UV resistance were compared using derived Owens-Wendt parameters. The surface of femtosecond-laser-textured steel after spontaneous hydrophobization was found to be significantly less stable under UV irradiation than surfaces treated with stearic acid or octyltrimethoxysilane modifiers.

Scalable Wettability Modification of Aluminum Surface through Single-Shot Nanosecond Laser Processing

Conversion of a regular metal surface to a superhydrophobic one has great appeal because of the wide range of potential applications such as anti-fouling, anti-corrosion, and anti-icing. One promising technique is to modify surface wettability by laser processing to form nano-micro hierarchical structures with various patterns, such as pillars, grooves, and grids, followed by an aging process in the air or additional chemical processes. Surface processing is typically a lengthy process. Herein, we demonstrate a facile laser technique that converts the surface wettability of aluminum from inherently hydrophilic to hydrophobic and superhydrophobic with single-shot nanosecond laser irradiation. A single shot covers a fabrication area of approximately 19.6 mm². The resultant hydrophobic and superhydrophobic effects persisted after six months. The effect of the incident laser energy on the surface wettability is studied, and the underlying mechanism of the wettability conversion through single-shot irradiation is suggested. The obtained surface shows a self-cleaning effect and the control of water adhesion. The single-shot nanosecond laser processing technique promises a fast and scalable method to produce laser-induced surface superhydrophobicity.

Enhancing Anticorrosion Resistance of Aluminum Alloys Using Femtosecond Laser-Based Surface Structuring and Coating

We report a robust two-step method for developing adherent and anticorrosive molybdenum (Mo)-based coatings over an aluminum (Al) 6061 alloy substrate using a femtosecond (fs) laser. The fs laser nanostructuring of Al 6061 alloy in air gives rise to regular arrays of microgrooves exhibiting superhydrophilic surface properties. The microstructured surface is further coated with an Mo layer using the fs-pulsed laser deposition (fs-PLD) technique. The combination of the two femtosecond laser surface treatments (microstructuring followed by coating) enabled the development of a highly corrosion-resistant surface, with a corrosion current of magnitude less than that of the pristine, the only structured, and the annealed alloy samples. The underlying mechanism is attributed to the laser-assisted formation of highly rough hierarchical oxide structures on the Al 6061 surface along with post heat treatment, which passivates the surface and provide the necessary platform for firm adhesion for Mo coating. Our results reveal that the corrosive nature of the Al-based alloys can be controlled and improved using a combined approach of femtosecond laser-based surface structuring and coating.

Self-Healing Superwetting Surfaces, Their Fabrications, and Properties

The research on superwetting surfaces with a self-healing function against various damages has progressed rapidly in the recent decade. They are expected to be an effective approach to increasing the durability and application robustness of superwetting materials. Various methods and material systems have been developed to prepare self-healing superwetting surfaces, some of which mimic natural superwetting surfaces. However, they still face challenges, such as being workable only for specific damages, external stimulation to trigger the healing process, and poor self-healing ability in the water, marine, or biological systems. There is a lack of fundamental understanding as well. This article comprehensively reviews self-healing superwetting surfaces, including their fabrication strategies, essential rules for materials design, and self-healing properties. Self-healing triggered by different external stimuli is summarized. The potential applications of self-healing superwetting surfaces are highlighted. This article consists of four main sections: (1) the functional surfaces with various superwetting properties, (2) natural self-healing superwetting surfaces (i.e., plants, insects, and creatures) and their healing mechanism, (3) recent research development in various self-healing superwetting surfaces, their preparation, wetting properties in the air or liquid media, and healing mechanism, and (4) the prospects including existing challenges, our views and potential solutions to the challenges, and future research directions.

Nanosecond Laser Induced Surface Structuring of Cadmium after Ablation in Air and Propanol Ambient

In the present study KrF Excimer laser has been employed to irradiate the Cadmium (Cd) targets for various number of laser pulses of 500, 1000, 1500 and 2000, at constant fluence of 3.6 J cm^-2. Scanning Electron Microscopy (SEM) analysis was utilized to reveal the formation of laser induced nano/micro structures on the irradiated target (Cd) surfaces. SEM results show the generation of cavities, cracks, micro/nano wires/rods, wrinkles along with re-deposited particles during irradiation in air, whereas subsurface boiling, pores, cavities and Laser Induced Periodic Surface Structures (LIPSS) on the inner walls of cavities are revealed at the central ablated area after irradiation in propanol. The ablated volume and depth of ablated region on irradiated Cd targets are evaluated for various number of pulses and is higher in air as compared to propanol ambient. Fast Fourier Transform Infrared spectroscopy (FTIR), Energy Dispersive X-ray Spectroscopy (EDS) and X-ray Diffraction (XRD) analyses show the presence of oxides and hydro-oxides of Cd after irradiation in propanol, whereas the existence of oxides is observed after irradiation in air ambient. Nano-hardness tester was used to investigate mechanical modifications of ablated Cd. It reveals an increase in hardness after irradiation which is more pronounced in propanol as compared to air.

Laser-Induced Slippery Liquid-Infused Surfaces with Anticorrosion and Wear Resistance Properties on Aluminum Alloy Substrates

Slippery liquid-infused surfaces (SLISs) are developed as a potential alternative to superhydrophobic surfaces (SHSs) to resolve the issues of poor durability in corrosion protection and wear resistance. In this work, we used a simple laser processing technology to prepare a SLIS on the aluminum alloy (7075) surface. The superhydrophobicities of the modified surface and the oil film formed by liquid injection make the corrosive medium difficult to directly contact the surface and thus have a significant effect on corrosion resistance. The water and oil repellent SLIS exhibits durable corrosion resistance and excellent tribological properties compared with the SHS. The anticorrosion and wear resistance performances provided by the composite film have been assessed by multiple methods including the electrochemical test, immersion test, and friction wear test. The results indicate that compared to the bare surface, laser-ablated surface (LAS), and fluoroalkyl silane-modified SHS, the SLIS composite coating has better corrosion resistance and wear resistance, which is of great significance to expand the potential applications of 7075 aluminum alloys. The work provides a research basis for expanding the practical application of SLISs in complex environments.

Fundamentals and utilization of solid/ liquid phase boundary interactions on functional surfaces

The affinity of macroscopic solid surfaces or dispersed nano- and bioparticles towards liquids plays a key role in many areas from fluid transport to interactions of the cells with phase boundaries. Forces between solid interfaces in water become especially important when the surface texture or particles are in the colloidal size range. Although, solid-liquid interactions are still prioritized subjects of materials science and therefore are extensively studied, the related literature still lacks in conclusive approaches, which involve as much information on fundamental aspects as on recent experimental findings related to influencing the wetting and other wetting-related properties and applications of different surfaces. The aim of this review is to fill this gap by shedding light on the mechanism-of-action and design principles of different, state-of-the-art functional macroscopic surfaces, ranging from self-cleaning, photoreactive or antimicrobial coatings to emulsion separation membranes, as these surfaces are gaining distinguished attention during the ongoing global environmental and epidemic crises. As there are increasing numbers of examples for stimulus-responsive surfaces and their interactions with liquids in the literature, as well, this overview also covers different external stimulus-responsive systems, regarding their mechanistic principles and application possibilities.

Near-Infrared-Light-Assisted Self-Healing Graphene-Thermopolyurethane Composite Films

Graphene-thermopolyurethane (G-TPU) composite films were fabricated and the effects of the TPU initial concentration, characteristics of TPU, and graphene loading on the electrical, mechanical, thermal, infrared thermal response and near-infrared-light-assisted self-healing properties of the composite films were investigated in detail. The experimental results demonstrate that the comprehensive performances of the composite film are related to the initial concentration of the TPU solution and the characteristics of the TPU and the graphene loading. The composite film prepared from TPU solution with low initial concentration can have conductivity under the condition of low graphene content. However, the composite film prepared with appropriate initial concentration of TPU solution and high graphene loading is conducive to obtain high conductivity. After 60 s of near-infrared illumination, the temperature of the composite film first increases and then decreases with the increase in graphene loading until it reaches saturation. The near-infrared light thermal response of the composite film with high graphene loading is related to the initial concentration of TPU solution, while the near-IR thermal response of the composite film with low graphene loading is independent of the initial concentration of TPU. The surface micro-cracks of the composite film almost disappeared after 10 min of near-infrared illumination. The resistance of the conductive composite film increases after healed. The composite film prepared with low melting point TPU is more favorable to obtain high near-IR thermal self-healing efficiency.

Fabrication of Superhydrophobic Gully-Structured Surfaces by Femtosecond Laser and Imprinting for High-Efficiency Self-Cleaning Rain Collection

Freshwater is considered an essential need for humanity. Moreover, it is important to collect and make full use of rainwater. This work utilizes a femtosecond laser to fabricate micro-nanostructures on aluminum alloy substrates as molds. Then, the structures are imprinted on cheap and wildly used polypropylene (PP) materials. The just-imprinted PP surfaces with instinctive surface energy and replicated micro-nanostructures have an excellent superhydrophobic property with contact angles greater than 160° and anisotropic sliding angles smaller than 5° in parallel directions and smaller than 10° in the vertical directions. A small-scale rain collection device formed by a combination of the superhydrophobic PP surfaces is used to investigate the effects of the rain collection efficiency and total surface area relating to manufacturing cost. The rain collection device formed by the imprinted PP surfaces has high rain collection efficiency in terms of the volume of the collected water per square centimeter. For the light rain, the rain collection efficiency can reach an approximated maximum of 90%, more than 100% efficiency improvement of the device formed by flat PP surfaces in some cases. Therefore, the rain collection device is helpful in collecting water from rains in arid areas.

Superhydrophilic-Superhydrophobic Multifunctional Janus Foam Fabrication Using a Spatially Shaped Femtosecond Laser for Fog Collection and Detection

Fog collection is an effective method for addressing water shortages in arid areas. By constructing a Janus structure with asymmetric wettability on its two sides, flexible and efficient fog capture can be achieved. However, in situ detection and fog collection on a Janus surface are still challenging tasks. Herein, a novel method for producing a superhydrophilic-superhydrophobic Janus fog collector is proposed; the method utilizes a combined process in which a spatially shaped femtosecond laser treatment (superhydrophilic) is applied to one side of a copper foam and a chemical replacement reaction (superhydrophobic) is applied to the other side of the copper foam. Two configurations of the Janus structure were designed to study different water transport behaviors. Furthermore, the Au micro-nanoparticle prepared adhered to the Janus structure, indicating the effectiveness of surface-enhanced Raman spectroscopy detection. The Janus foam shows excellent sensitivity and stability on testing the fog mixed with rhodamine 6G. This surface allows for the simultaneous collection and detection of fog, which can provide insights into the preparation of Janus multifunction structures and how such structures can play a key role in the subsequent purification and usage of water resources.