Laser texturing of AA2024 alloy: A simplified approach to improve corrosion resistance and achieve superhydrophobicity

Despite its susceptibility to corrosion, AA2024 alloy is extensively used in the aerospace industry due to its favourable mechanical properties. Conventional corrosion protection methods frequently rely on hazardous chemicals and complex multi-step processes, which limits their sustainability and scalability. This study focuses on the development of an environmentally friendly, simplified laser-based method that structures surfaces in a single scan, producing line-like microstructures that achieve superhydrophobicity. The surfaces present static water contact angles of up to 160° and roll-off angles below 5°. The laser treatment results in the creation of a thicker Al2O3 oxide layer on the surfaces, as evidenced by FIB-STEM images and the chemical characterization through XPS analysis. Consequently, the treated surfaces exhibit a notable enhancement in polarization resistance, rising from 23.6 kΩ cm2 to 159.5 kΩ cm2. This study provides insights into the viability of a novel, simple, laser-based approach for corrosion protection that exhibits additional wetting properties.