Design of Dual-Path Antibacterial Aluminum Alloy Based on ZnO Sputtering and Surface Roughness Control

Antibacterial alloys based on aluminum alloys have become a hot topic. However, most existing research is limited to a single antibacterial mechanism and may suffer from insufficient long-term efficacy, making it difficult to meet the requirements of large-scale production and applications in diverse scenarios. Therefore, the development of a synergistic, multi-mechanism antibacterial modification strategy for aluminum alloys is urgently needed. In this study, a dual-mechanism antibacterial aluminum alloy was developed by combining surface-structure-assisted antibacterial activity with ZnO-mediated antibacterial activity. By adjusting various process parameters, the surface roughness of the aluminum alloy and the microstructure of ZnO were regulated. This study systematically investigated the effects of aluminum-alloy surface roughness and ZnO microstructure on the antibacterial performance of the composite system. In vitro antibacterial test results showed that aluminum alloy subjected to the dual-mechanism modification exhibited excellent antibacterial activity: the antibacterial rate against E. coli and S. aureus reached 95 and 90%, respectively. This study provides a strategy to construct the dual-pathway synergistic antibacterial aluminum alloy, which possesses great potential in applications such as food processing, medical devices, and public health.