Fabricating aluminium surfaces with superhydrophobic and ice-repellent properties present nowadays a challenging task. In this work, multifunctional structures are manufactured by direct laser writing and direct laser interference patterning methods using pulsed infrared laser radiation (1064 nm). Different periodic patterns with feature sizes ranging from 7.0 to 50.0 µm are produced. In addition, hierarchical textures are produced combining both mentioned laser based methods. Water contact angle tests at room temperature showed that all produced patterns reached the superhydrophobic state after 13 to 16 days. In addition, these experiments were repeated at substrate temperatures from −30 °C to 80 °C allowing to determine three wettability behaviours as a function of the temperature. The patterned surfaces also showed ice-repellent properties characterized by a near three-fold increase in the droplets freezing times compared to the untreated samples. Using finite element simulations, it was found that the main reason behind the ice-prevention is the change in the droplet geometrical shape due to the hydrophobic nature of the treated surfaces. Finally, dynamic tests of droplets imping the treated aluminium surfaces cooled down to −20 °C revealed that only on the hierarchically patterned surface, the droplets were able to bounce off the substrate.

Ice-building up on the leading edge of wings and other surfaces exposed to icing atmospheric conditions can negatively influence the aerodynamic performances of aircrafts. In the past, research activities focused on understanding icing phenomena and finding effective countermeasures. Efforts have been dedicated to creating coatings capable of reducing the adhesion strength of ice to a surface. Nevertheless, coatings still lack functional stability, and their application can be harmful to health and the environment. Pulsed laser surface treatments have been proven as a viable technology to induce icephobicity on metallic surfaces. However, a study aimed to find the most effective microstructures for reducing ice adhesion still needs to be carried out. This study investigates the variation of the ice adhesion strength of micro-textured aluminum surfaces treated using laser-based methods. The icephobic performance is tested in an icing wind tunnel, simulating realistic icing conditions. Finally, it is shown that optimum surface textures lead to a reduction of the ice adhesion strength from originally 57 kPa down to 6 kPa, corresponding to a relative reduction of ~90%. Consequently, these new insights will be of great importance in the development of functionalized surfaces, permitting an innovative approach to prevent the icing of aluminum components.

Laser-microtextured surfaces have gained an increasing interest due to their enormous spectrum of applications and industrial scalability. Direct laser interference patterning (DLIP) and the well-established direct laser writing (DLW) methods are suitable as a powerful combination for the fabrication of single (DLW or DLIP) and multi-scale (DLW+DLIP) textures. In this work, four-beam DLIP and DLW were used independently and combined to produce functional textures on aluminum. The influence of the laser processing parameters, such as the applied laser fluence and the number of pulses, on the resulting topography was analyzed by confocal microscopy and scanning electron microscopy. The static long-term and dynamic wettability characteristics of the laser-textured surfaces were determined through water contact angle and hysteresis measurements, revealing superhydrophobic properties with static contact angles up to 163° and hysteresis as low as 9°. The classical Cassie–Baxter and Wenzel models were applied, permitting a deeper understanding of the observed wetting behaviors. Finally, mechanical stability tests revealed that the DLW elements in the multi-scale structure protects the smaller DLIP features under tribological conditions.

Refractive index modification by laser micro-structuration of diffractive optical devices in ophthalmic polymers has recently been applied for refractive correction in the fields of optics and ophthalmology. In this work, Safrofilcon-A hydrogel, used as soft contact lenses, was processed by direct laser interference patterning (DLIP) to fabricate linear periodic patterns on the surface of the samples. Periodic modulation of the surface was attained under two-beam interference by using a Q-switched laser source with emission at 263 nm and 4 ns pulse duration. Features of processed areas were studied as a function of both the interference spatial period and the laser fluence. Optical confocal microscopy used to evaluate the topography of the processed samples showed that both structured height and surface roughness increased with laser fluence. Static water contact angle (WCA) measurements were carried out with deionized water droplets on the structured areas to evaluate the hydration properties of DLIP structures. It was observed that the laser structured areas induced a delay in the hydration process. Finally, microstructural changes induced in the structured areas were assessed by confocal micro-Raman spectroscopy showing that at low laser fluences the polymer structure remained almost unaltered. In addition, Raman spectra of hydrated samples recovered the original shape of areas structured at low laser fluence.

In this work, the fabrication of multifunctional periodic microstructures on pure aluminium is presented. Three different geometries were fabricated with feature sizes ranging between 7 µm and 50 µm by using laser-based microstructuring methods. In detail, nanosecond pulsed direct laser writing and picosecond pulsed direct laser interference patterning were used with infrared laser radiation. The wetting characteristics of these structures were investigated performing static water contact angle measurements as well as by measuring the contact angle hysteresis and the sliding angle. The final wetting results show constant static contact angles above 150°, permitting the water droplets to roll off the substrate as well as collecting contamination at the same time. This self-cleaning effect led to a reduction of up to 94% of the spread of 1 µm sized manganese oxide particles. In addition, the freezing time required for droplets laying on the patterned surfaces was increased nearly by 300% at a temperature of 20 °C below zero. Finally, the results are compared to finite element simulations of heat transfer.