Temperature Dependent Anti-Icing Performance of the Microstructure Surface: Wettability Change and Ice Nucleation

Icing has caused much inconvenience to daily production and life. A microstructure surface possessing a hydrophobic property is an effective countermeasure to impede or delay ice formation for anti-icing purposes. However, surface wettability is sensitive to environmental conditions such as temperature and humidity. In the worst-case scenario, a Wenzel state drop forms and causes degradation of surface anti-icing performance. In this study, a copper alloy was used as the testing sample, and the surface was fabricated using mechanical polishing, micro-milling machining and ultrafast laser etching to form the desired topology and microstructures. The hydrophobicity and icephobicity of four types of surfaces including smooth flat, rough flat, rough microstructure and smooth microstructure were tested by depositing droplets from room temperature to an ultralow subzero temperature condition (below −30 °C). At −10 °C, the icephobicity of the surface was consistent with the surface wettability at room temperature. However, the hydrophobicity of the surface slightly decreased, and a Wenzel state drop formed on the microstructure surface. At −30 °C, the apparent contact angle and the ice–substrate contact area were mainly affected by ice nucleation rather than surface wettability. The bottom layer of the droplet froze after immediate contact with the substrate due to a higher degree of supercooling. The formation of a Cassie state drop reduced the ice–substrate contact area and created more air cushions, which facilitated the extension of the icing process of the drop. The enhancement in the anti-icing performance of the microstructure surface was analyzed from a theoretical basis.