Study of Micro- and Nanopatterned Aluminum Surfaces Using Different Microfabrication Processes for Water Management

Superhydrophobic surfaces demonstrate extreme water-repellence, promoting drop-wise over film-wise condensation, increasing liquid mobility, and reducing thermal resistance for heat-exchanger applications. Introducing topographic structures can lead to modified surface free energy, as inspired by natural systems like the lotus leaf, potentially allowing coating-free ice- and frost-free surfaces under certain conditions. This work presents a study of coating-free aluminum micro/nanopatterns fabricated using micromilling or laser-etching techniques and the resultant wetting properties. Our review and experiments clarify the roles of line-edge-roughness and microstructural geometry from each microfabrication technique, which manifests in technique-specific nano- to midmicro-scale roughness, producing a hierarchical structure in both cases. For micromilling, line-edge-roughness consists of jagged burrs of 1-8 μm thickness with 10-25 μm periodicity along the microlines with constantly changing height on the order of 1-20 μm. These effects simultaneously raise the water contact angle from 52° (unprocessed aluminum) up to 136° but with strong edge pinning effects. On the other hand, laser-etched surfaces exhibit line-edge-roughness with a microstructure of 3-20 μm width and 5-10 μm in height superimposed with evenly spread spikes of 50-250 nm. This results in a high contact angle (>150°) coupled with a low contact angle hysteresis (<15°), promoting superhydrophobicity on a coating-free aluminum surface. It is also shown that for certain cases, line-edge-roughness is more important for the resultant wetting properties than the structure geometry.