Scalable Advanced Dual-Engineered Superhydrophobic Aluminum Surfaces for Industrial-Grade Corrosion Protection
Year: 2025
Type: article
Abstract: Superhydrophobic coatings on aluminum play a crucial role in enhancing corrosion resistance in harsh marine and chloride-rich environments. This study introduces a scalable fabrication method for superhydrophobic aluminum surfaces exhibiting outstanding corrosion resistance. The process involves a two-step technique combining chemical etching with atmospheric pressure chemical vapor deposition (AP-CVD) of perfluorooctyltriethoxysilane (PFOTES). Hierarchical micro- and nanostructures were created by HCl etching, followed by conformal PFOTES functionalization to impart low surface energy. The fabricated surfaces demonstrated water contact angles reaching as high as 175°, coupled with very-low-contact-angle hysteresis, indicative of the Cassie–Baxter wetting state. Electrochemical analyses in saline environments demonstrated a substantial increase in charge transfer resistance and a reduction in corrosion rates by more than an order of magnitude compared to uncoated aluminum, with inhibition efficiencies exceeding 98%. Extended salt spray testing corroborated the durability and efficacy of the dual-modified surfaces. This facile and cost-effective method offers promising prospects for multifunctional aluminum components in marine, infrastructure, and aerospace applications where long-term protection against aggressive environments is required.
Source: Metals
DOI: 10.3390/met15111248
Authors: N. Rahul, Ho-Eon Sung, Sang Won Lee, Min-Suk Oh
Language: English
Subfield: Surfaces, Coatings and Films
Field: Materials Science
Domain: Physical Sciences
Open Access status: gold
Estimated APC paid: $3,137
OpenAlex ID: W4416298776