| Abstract Scope |
A PFAS-free, triple-scale superhydrophobic surface with dual-mode self-healing functionality was fabricated on AA6061 using a scalable, laser texturing followed by hydrothermal treatment and surface chemistry modification. Nanosecond laser texturing produced micro- and submicron-scale surface features, while hydrothermal treatment induced an in-situ growth of γ-boehmite nanoflakes, establishing a hierarchical triple-scale morphology. The structured surface was then functionalized with a silane–polymer blend, applied at room temperature, and cured at 90 °C. The resulting coating exhibited excellent water repellency, with a contact angle of ~160°, roll-off angle of ~2°, hysteresis of ~2.6°, and surface energy as low as ~2.04 mN/m. Upon mechanical damage, the surface demonstrated functional recovery, as nanostructures were regenerated via hydrothermal treatment. Additionally, mild heating enabled capillary-driven viscoelastic flow of surface chemistry in the regenerated nanostructures in the damaged regions, resulting in the restoration of superhydrophobicity. SEM, Confocal, and XPS analyses were performed to analyze the regenerated morphology and chemical composition. |