An international research team from Rice University and the University of Edinburgh has pioneered a cost-effective method for creating precisely patterned aluminum surfaces with tailored wettability properties. Published in Langmuir, this breakthrough enables scalable production of surfaces with alternating superhydrophobic and hydrophilic zones, significantly enhancing liquid transport for thermal management applications.
Innovative Masking Technique Enables Precision Engineering
The researchers developed a novel approach combining blade-cut vinyl masking with commercial lacquer resin to create patterns as small as 1.5 mm on aluminum substrates. A two-step etching process produces micro- and nanotextured zones with distinct wettability characteristics, achieving resolution comparable to expensive photolithography methods at a fraction of the cost. The technique’s scalability makes it particularly valuable for industrial applications requiring large-area patterning.
Enhanced Thermal Performance Through Surface Engineering
The patterned surfaces demonstrate superior performance in condensation heat transfer, with key advantages:
- 50% faster droplet shedding compared to homogeneous surfaces
- Customizable wettability gradients for optimized liquid transport
- Significant thermal emissivity contrasts between zones (up to 30% variation)
- Maintains aluminum’s native thermal conductivity (200+ W/m·K)
“By controlling surface wettability and thermal properties at this scale, we’re enabling new cooling strategies for high-power electronics,” explained Daniel J. Preston, co-corresponding author and Rice University mechanical engineering professor.
Broad Industrial Applications
The technology addresses critical needs across multiple sectors:
- Electronics Cooling: Prevents overheating in data center servers through enhanced condensation
- Aerospace: Reduces ice accumulation on aircraft surfaces by 40% in testing
- Energy Systems: Improves wind turbine performance in cold climates
- Automotive: Optimizes heat exchanger efficiency in electric vehicle batteries
Geoff Wehmeyer, co-corresponding author at Rice, noted: “This brings surface engineering capabilities to aluminum’s existing advantages of conductivity, lightness and affordability.”
Collaborative Research Driving Innovation
Supported by the Rice-Edinburgh Strategic Collaboration Award program with additional funding from NASA and NSF, the project combines complementary expertise in surface science and thermal engineering. The team is now working with industrial partners to transition the technology from lab-scale demonstrations to commercial applications, with pilot production expected within two years.
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