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Wire Electrochemical Machining of Nickel-Based Superhydrophobic Surface with Array Structures
Bingzhen Zhang1,2, Binghan Wu1, Zhenjing Duan1
1State Key Laboratory of High-performance Precision Manufacturing, Dalian University of Technology, Dalian, Liaoning 116024, China.
Langmuir : the ACS Journal of Surfaces and Colloids
|August 28, 2025
Summary
Researchers developed a novel method using wire electrochemical machining (WECM) to create superhydrophobic nickel surfaces. This technique enhances corrosion resistance and antifouling properties for demanding engineering applications.
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.
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