Wire Electrochemical Machining of Nickel-Based Superhydrophobic Surface with Array Structures

Area of Science:

• Materials Science
• Surface Engineering
• Electrochemistry

Background:

• Nickel-based materials are vital for aerospace and marine applications but are susceptible to corrosion in harsh environments.
• Existing methods for creating superhydrophobic surfaces on nickel, like laser etching, have limitations such as thermal damage and poor accuracy.
• Fabricating complex submillimeter arrays on nickel surfaces for enhanced hydrophobicity is challenging.

Purpose of the Study:

• To develop an effective strategy for fabricating complex micro/nanostructured superhydrophobic surfaces on nickel.
• To enhance the corrosion resistance and antifouling properties of nickel-based materials for extreme environments.
• To overcome the limitations of traditional fabrication methods for creating advanced surface topographies.

Main Methods:

• Precise three-dimensional wire electrochemical machining (WECM) path planning was employed to fabricate inverted cone- and gourd-shaped arrays.
• A secondary etching process using optimized nitric acid was performed to create hierarchical micro/nanorough structures.
• Surface modification with fluorosilane was applied to achieve superhydrophobicity.

Main Results:

• Successfully fabricated complex inverted cone- and gourd-shaped arrays on nickel surfaces.
• Achieved hierarchical micro/nanorough structures, significantly enhancing surface roughness.
• The modified surface exhibited a water contact angle of 155°, demonstrating excellent superhydrophobicity.
• The developed surfaces showed enhanced corrosion resistance and antifouling capabilities.

Conclusions:

• The combined approach of macroscopic array design and microscopic structure regulation offers an effective solution for superhydrophobic surface fabrication on nickel.
• This method significantly improves the protection of nickel-based surfaces against corrosion and fouling in extreme conditions.
• The study presents a viable pathway for advancing the performance of nickel materials in demanding engineering sectors.