Electrochemical Activation and Nanostructuring of NiCr Mesh for Superhydrophobic Anti-Icing and Energy-Efficient Electrothermal De-Icing

Nichrome (NiCr) heaters are challenging to functionalize because their native chromium-rich spinel passivation layer inhibits strong metallurgical bonding and uniform electrochemical growth. We report a plating-compatible wet-chemical method that first activates NiCr using Wood's nickel strike, chemically removing the oxide while depositing a thin, adherent nickel seed layer, and subsequently electrodeposits hierarchical nickel nanostructures that are finally modified with a low-surface-energy monolayer. The resulting surface exhibits superhydrophobicity (static contact angle ≈158°, sliding angle <5°) while maintaining its electrical heating performance. The superhydrophobic state remains stable after 1000 on/off thermal cycles. A strong synergy between the passive anti-icing property of the superhydrophobic surface and the active heating function enables a highly efficient "interfacial melting and sliding" deicing mechanism, reducing energy consumption for ice removal by over 85% compared with that of a pristine heater. This study presents a robust and plating-compatible methodology for converting chemically inert alloys into high-performance, multifunctional materials for energy-efficient phase-change applications.