Ultrafast Laser-Assisted Hybrid Fabrication of Biomimetic Superhydrophobic Surfaces: Strategies, Mechanisms, and Applications

Abstract

Metal matrix composites hold significant strategic importance in aerospace and marine engineering for their excellent mechanical properties and chemical stability. However, their surface interfaces are often vulnerable to degradation caused by corrosion, ice accretion, and frictional wear, which severely limits their long-term functionality in practical applications. Inspired by biological surfaces such as lotus leaves and butterfly wings, bio-inspired superhydrophobic surface technology provides novel solutions through the construction of micro/nanostructures and low-surface-energy characteristics. Ultrafast laser processing enables precise submicron fabrication with ultrashort pulses. Nevertheless, inherent defects like recast layers and microcracks in single-laser processing compromise surface quality and functional stability. Recent studies have demonstrated that integrating ultrafast laser processing with chemical deposition, surface coating, or other synergistic techniques enables the formation of robust, multi-scale structures with improved structural strength and functional stability. This hybrid strategy not only strengthens surface resistance against corrosive media, ice nucleation, and bio-adhesion but also offers innovative approaches for applications including directional droplet transport and intelligent oil-water separation. This review systematically summarizes recent advances in ultrafast laser hybrid technology for constructing superhydrophobic surfaces on metal substrates, elucidates fundamental wetting theory models and processing mechanisms, discusses current anti-corrosion and anti-icing applications, and proposes future development directions.