Various surface characterization techniques were used to study the modified surface chemistry of superhydrophobic aluminum alloy surfaces prepared by immersing the substrates in an aqueous solution containing sodium hydroxide and fluoroalkyl-silane (FAS-17) molecules. The creation of a rough micronanostructure on the treated surfaces was revealed by scanning electron microscopy (SEM). X-ray photoelectron spectroscopy (XPS) and infrared reflection absorption spectroscopy (IRRAS) confirmed the presence of low surface energy functional groups of fluorinated carbon on the superhydrophobic surfaces. IRRAS also revealed the presence of a large number of OH groups on the hydrophilic surfaces. A possible bonding mechanism of the FAS-17 molecules with the aluminum alloy surfaces has been suggested based on the IRRAS and XPS studies. The resulting surfaces demonstrated water contact angles as high as ∼166° and contact angle hystereses as low as ∼4.5°. A correlation between the contact angle, rms roughnesses, and the chemical nature of the surface has been elucidated.

A simple one-step process has been developed to render aluminum alloy surfaces superhydrophobic by immersing the aluminum alloy substrates in a solution containing NaOH and fluoroalkyl-silane (FAS-17) molecules. Scanning electron microscopy (SEM), X-ray photoelectron spectroscopy (XPS) and water contact angle measurements have been performed to characterize the morphological features, chemical composition and superhydrophobicity of the surfaces. The resulting surfaces provided a water contact angle as high as ∼162° and a contact angle hysteresis as low as ∼4°. The study indicates that it is possible to fabricate superhydrophobic aluminum surfaces easily and effectively without involving the traditional two-step processes.

In this study, the potential applications of Al-Mn-Mg 3004 alloy at elevated temperature have been evaluated through the systematic study of the precipitation behavior of α-Al(MnFe)Si dispersoids and their effect on material properties during precipitation treatment and long-term thermal holding. The results demonstrate a significant dispersion strengthening effect caused by the precipitation of fine uniformly distributed dispersoids during precipitation treatment. The peak compression yield strength (YS) at 300°C of the experimental 3004 alloy can reach as high as 78 MPa due to a large volume fraction (~2.95 vol. %) of α-Al(MnFe)Si dispersoids. The dispersoids are found to be thermally stable at 300°C for up to 1000 h of holding, leading to consistently high mechanical performance and creep resistance. The superior and stable YS and creep resistance at 300°C enables the 3004 alloy to be applied to weight-sensitive applications at elevated temperatures.

Highlights• Superhydrophobic copper surfaces by a one-step electrochemical modification process in an ethanolic stearic acid solution.• Analysis of the corrosion properties of as-received, hydrophobic and superhydrophobic copper surfaces.• The corrosion resistance of the superhydrophobic surface is found to be 1220 kΩ cm 2 as compared to as-received bare copper surface 1 kΩ cm 2 . AbstractSuperhydrophobic copper surfaces have been prepared by a one-step electrochemical modification process in an ethanolic stearic acid solution. In this work, the corrosion properties of hydrophobic copper surface and superhydrophobic copper surfaces were analyzed by means of electrochemical analyses and compared with that of as-received bare copper substrate. The decrease of corrosion current density (icorr) as well as the increase of polarization resistance (Rp) obtained from potentiodynamic polarization curves revealed that the superhydrophobic film on the copper surfaces improved the corrosion resistance performance of the copper substrate.Graphical Abstract