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Updated: May 21, 2026
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Fabrication of Superhydrophobic Metal Surfaces for Anti-Icing Applications
Published on: August 15, 2018
One-step process for superhydrophobic metallic surfaces by wire electrical discharge machining
Won Gyu Bae1, Ki Young Song, Yudi Rahmawan
1Interdisciplinary Program of Bioengineering and ‡School of Mechanical and Aerospace Engineering, Seoul National University , Seoul 151-742, Korea.
ACS Applied Materials & Interfaces
|June 27, 2012
Summary
A new wire electrical discharge machining (WEDM) method creates dual-scale superhydrophobic aluminum surfaces in one step. This process generates microscale patterns and nanoscale roughness for stable water repellency without chemicals.
Area of Science:
- Materials Science
- Surface Engineering
- Tribology
Background:
- Superhydrophobic surfaces offer advanced properties like self-cleaning and anti-icing.
- Fabricating durable superhydrophobic surfaces on metals often requires complex multi-step processes.
- Controlling surface topography at multiple scales is crucial for achieving stable superhydrophobicity.
Purpose of the Study:
- To develop a direct, one-step method for creating dual-scale superhydrophobic metallic surfaces.
- To investigate the spontaneous formation of dual-scale structures during wire electrical discharge machining (WEDM).
- To analyze the wetting behavior and stability of the fabricated superhydrophobic surfaces.
Main Methods:
- Utilized wire electrical discharge machining (WEDM) on Al 7075 alloy.
- Programmed WEDM to create primary microscale sinusoidal patterns (200-500 μm wavelength).
- Characterized the spontaneously formed secondary microcrater roughness and measured surface wettability (contact angle, hysteresis).
Main Results:
- Successfully fabricated dual-scale superhydrophobic surfaces on Al 7075 alloy in a single step.
- Observed a primary microscale sinusoidal pattern and secondary microcrater roughness (Ra: 0.41-4.16 μm).
- Achieved a high static contact angle of 156° and low hysteresis (<3°), indicating stable superhydrophobicity.
- Theoretical modeling suggested Cassie state wetting on secondary roughness and Wenzel or Cassie state on primary roughness.
Conclusions:
- WEDM is an effective one-step method for fabricating dual-scale superhydrophobic metallic surfaces.
- The combination of Al 7075's low surface energy and dual-scale topography leads to stable superhydrophobicity.
- Optimized WEDM parameters (serial cutting, power) can yield highly stable superhydrophobic surfaces.
