Micro- and nanostructure formation on duralumin by femtosecond laser processing for optical camouflage and diverse industrial applications
Source abstract
Abstract
Abstract Femtosecond laser processing enables the formation of complex micro- and nanostructures on duralumin surfaces, resulting in a significant reduction of optical reflectivity across the visible and near-infrared spectrum. This laser-induced blackening is achieved without the need for additional coatings, producing surfaces that are highly resistant to mechanical wear, thermal stress, and most chemical exposures. Reflectivity measurements confirm that the treated surfaces maintain low reflectance, while morphological and compositional analyses reveal the development of light-trapping hierarchical structures and a durable oxide-rich surface layer. Mechanical and adhesion tests demonstrate increased hardness and improved bonding capabilities, and thermal as well as chemical durability tests indicate stable performance under demanding conditions. These combined properties make femtosecond laser-structured duralumin a promising material for stealth and camouflage applications, particularly in aerospace and drone technologies, where both durability and low visibility are essential.
Source: crossref · Quality: baseline
Research context
OpenAlex topics: Laser Material Processing Techniques · Thermal Radiation and Cooling Technologies · Silicon Nanostructures and Photoluminescence
SciVX discovery tags are terminology-based. OpenAlex topics are source-provided classifications.
References (38)
Show source-provided references
1. M. Li, D. Liu, H. Cheng, L. Peng, M. Zu, Manipulating metals for adaptive thermal camouflage. Sci. Adv. 6, 1–10 (2020). https://doi.org/10.1126/sciadv.aba349410.1126/sciadv.aba3494 ↗
2. C. Yu, Y. Li, X. Zhang, X. Huang, V. Malyarchuk, S. Wang, Y. Shi, L. Gao, Y. Su, Y. Zhang, H. Xu, R.T. Hanlon, Y. Huang, J.A. Rogers, Adaptive optoelectronic camouflage systems with designs inspired by cephalopod skins. Proc. Natl. Acad. Sci. U. S. A. 111, 12998–13003 (2014). https://doi.org/10.1073/pnas.141049411110.1073/pnas.1410494111 ↗
3. F. Ahmed, N. Qassmi, S.W. Fatima Rizvi, A. Al-Ali, Unveiling the Shadows: Leveraging Current Drone Detection Vulnerabilities to Design and Build a Stealth Drone, 2nd Int. Conf. Unmanned Veh. Syst. UVS 2024 (2024) 1–10. https://doi.org/10.1109/UVS59630.2024.1046716810.1109/UVS59630.2024.10467168 ↗
4. S. Hu, X. Yuan, W. Ni, X. Wang, A. Jamalipour, Visual camouflage and online trajectory planning for unmanned aerial vehicle-based disguised video surveillance: recent advances and a case study. IEEE Veh. Technol. Mag. 18, 48–57 (2023). https://doi.org/10.1109/MVT.2023.326332910.1109/MVT.2023.3263329 ↗
5. A.Y. Vorobyev, C. Guo, Direct femtosecond laser surface nano/microstructuring and its applications. Laser Photonics Rev. 7, 385–407 (2013). https://doi.org/10.1002/lpor.20120001710.1002/lpor.201200017 ↗
6. J. Yang, F. Luo, T.S. Kao, X. Li, G.W. Ho, J. Teng, X. Luo, M. Hong, Design and fabrication of broadband ultralow reflectivity black Si surfaces by laser micro/nanoprocessing. Light Sci. Appl. 3, 0 (2014). https://doi.org/10.1038/lsa.2014.6610.1038/lsa.2014.66 ↗
7. H. Huang, L.-M. Yang, S. Bai, J. Liu, Blackening of metals using femtosecond fiber laser. Appl. Opt. 54, 324 (2015). https://doi.org/10.1364/AO.54.00032410.1364/AO.54.000324 ↗
8. J. Dutta Majumdar, I. Manna, Laser material processing. Int. Mater. Rev. 56, 341–388 (2011). https://doi.org/10.1179/1743280411Y.000000000310.1179/1743280411Y.0000000003 ↗
9. Z. Ou, M. Huang, F. Zhao, The fluence threshold of femtosecond laser blackening of metals: the effect of laser-induced ripples. Opt. Laser Technol. 79, 79–87 (2016). https://doi.org/10.1016/j.optlastec.2015.11.01810.1016/j.optlastec.2015.11.018 ↗
10. I.N. Zavestovskaya, Laser nanostructuring of materials surfaces. Quantum Electron. 40, 942–954 (2010). https://doi.org/10.1070/QE2010v040n11ABEH01444710.1070/QE2010v040n11ABEH014447 ↗
11. B. Hopp, M. Sámi, T. Gera, J. Budai, G. Ballai, L. Tóth, J. Bohus, G. Gulyás, T. Szörényi, T. Smausz, Femtosecond laser darkened copper surfaces: characterization for possible application as laser beam blocker. Surf. Interfaces (2024). https://doi.org/10.1016/j.surfin.2024.10474510.1016/j.surfin.2024.104745 ↗
12. T. Nawaz, A. Ali, S. Ahmad, P. Piatkowski, A.S. Alnaser, Enhancing anticorrosion resistance of aluminum alloys using femtosecond laser-based surface structuring and coating. Nanomaterials (2023). https://doi.org/10.3390/nano1304064410.3390/nano13040644 ↗
13. F. Tajti, B. Petrovics, Optimization of bonding technology for aluminium foams using femtosecond laser beam pulses, IOP Conf. Ser. Mater. Sci. Eng. 1246, 012027 (2022). https://doi.org/10.1088/1757-899x/1246/1/01202710.1088/1757-899x/1246/1/012027 ↗
14. L.B. Boinovich, E.B. Modin, A.R. Sayfutdinova, K.A. Emelyanenko, A.L. Vasiliev, A.M. Emelyanenko, Combination of functional nanoengineering and nanosecond laser texturing for design of superhydrophobic aluminum alloy with exceptional mechanical and chemical properties. ACS Nano 11, 10113–10123 (2017). https://doi.org/10.1021/acsnano.7b0463410.1021/acsnano.7b04634 ↗
15. Y. Guo, H. Zhao, D. Zhai, Z. Gao, Q. Li, X. Chen, G. Zhao, Micro/nano dual-scale porous surface structure of the Al alloys and improvement on the joint strength with carbon fiber reinforced PA 6 thermoplastic. Compos. Part B Eng. 249, 110407 (2023). https://doi.org/10.1016/j.compositesb.2022.11040710.1016/j.compositesb.2022.110407 ↗
16. A.A. Andarabi, K. Shelesh-Nezhad, T.N. Chakherlou, The effect of laser surface structuring patterns on the interfacial resistance of aluminum joints bonded with epoxy adhesive. Int. J. Adhes. Adhes. 114, 103101 (2022). https://doi.org/10.1016/j.ijadhadh.2022.10310110.1016/j.ijadhadh.2022.103101 ↗
17. S. Sharma, S. Ahmad, U. Prasad, R.B. Harikrishna, K. Hsu, A.N.M. Kannan, R.R. Gangavarapu, Review of Laser-Based surface Nanotexturing for enhanced light absorption and photoelectrochemical water Splitting, ACS appl. Nano Mater. (2023). https://doi.org/10.1021/acsanm.3c0408310.1021/acsanm.3c04083 ↗
18. K.C. Phillips, H.H. Gandhi, E. Mazur, S.K. Sundaram, Ultrafast laser processing of materials: a review. Adv. Opt. Photonics. 7, 684 (2015). https://doi.org/10.1364/aop.7.00068410.1364/aop.7.000684 ↗
19. K.M. Tanvir Ahmmed, C. Grambow, A.M. Kietzig, Fabrication of micro/nano structures on metals by femtosecond laser micromachining. Micromachines. 5, 1219–1253 (2014). https://doi.org/10.3390/mi504121910.3390/mi5041219 ↗
20. A. Bharatish, S. Soundarapandian, Influence of femtosecond laser parameters and environment on surface texture characteristics of metals and non-metals – state of the art. Lasers Manuf. Mater. Process. 5, 143–167 (2018). https://doi.org/10.1007/s40516-018-0059-110.1007/s40516-018-0059-1 ↗
21. J. Han, B. Göksel, M. Li, J. Vleugels, A. Braem, S. Castagne, Effects of femtosecond laser surface texturing on mechanical properties and low temperature degradation of alumina toughened zirconia. J. Eur. Ceram. Soc. 44, 4196–4209 (2024). https://doi.org/10.1016/j.jeurceramsoc.2024.01.03610.1016/j.jeurceramsoc.2024.01.036 ↗
22. L. Hu, D. Yan, T. Zou, J. Xu, L. Li, R. Zhang, J. Yang, Ultra-corrosion-resistant aluminum alloys achieved by femtosecond laser complete remediation of microarc oxidation defects. Appl. Surf. Sci. 663, 160160 (2024). https://doi.org/10.1016/j.apsusc.2024.16016010.1016/j.apsusc.2024.160160 ↗
23. K. Li, X. Lei, Z. Ding, S. Liu, W. Zhou, F. Liu, Super anti-corrosion surface of Al-Li alloy via femtosecond laser ablation treatment in water. J. Alloys Compd. 971, 172704 (2024). https://doi.org/10.1016/j.jallcom.2023.17270410.1016/j.jallcom.2023.172704 ↗
24. S. Du, S. Zhang, J. Wang, Z. Lv, Z. Xu, C. Liu, J. Liu, B. Liu, Energy flow of aerospace aluminum scraps cycle and advanced integration principles for upcycling technologies: a review. J. Clean. Prod. 448, 141176 (2024). https://doi.org/10.1016/j.jclepro.2024.14117610.1016/j.jclepro.2024.141176 ↗
25. D.K. Ammisetti, S.S.H. Kruthiventi, S. Vinjavarapu, N.N. Babu, J.R. Gandepudi, S.K. Battula, A review on reinforcements, fabrication methods, and mechanical and wear properties of titanium metal matrix composites. J. Eng. Appl. Sci. 71, 1–23 (2024). https://doi.org/10.1186/s44147-024-00392-z10.1186/s44147-024-00392-z ↗
26. T. Trzepieciński, S.M. Najm, T. Pepelnjak, K. Bensaid, M. Szpunar, Incremental sheet forming of metal-based composites used in aviation and automotive applications. J. Compos. Sci. (2022). https://doi.org/10.3390/jcs610029510.3390/jcs6100295 ↗
27. H. Fan, J. Hu, Y. Wang, H. Zhang, W. Guo, J. Li, S. Xu, H. Li, P. Liu, A review of laser additive manufacturing (LAM) aluminum alloys: methods, microstructures and mechanical properties. Opt. Laser Technol. 175, 110722 (2024). https://doi.org/10.1016/j.optlastec.2024.11072210.1016/j.optlastec.2024.110722 ↗
28. F. Ruffino, M.G. Grimaldi, Nanostructuration of thin metal films by pulsed laser irradiations: a review. Nanomaterials (2019). https://doi.org/10.3390/nano908113310.3390/nano9081133 ↗
29. A. Afanasiev, I. Ilyakov, B. Shishkin, N. Bityurin, Nanopatterning of the dielectric surface by a pair of femtosecond laser pulses of different colors through a monolayer of microspheres. Opt. Express 31, 12423 (2023). https://doi.org/10.1364/oe.48229110.1364/oe.482291 ↗
30. M. Liu, M.T. Li, S. Xu, H. Yang, H.B. Sun, Bioinspired superhydrophobic surfaces via laser-structuring. Front. Chem. 8, 1–6 (2020). https://doi.org/10.3389/fchem.2020.0083510.3389/fchem.2020.00835 ↗
31. N. Berezovska, I. Dmitruk, A. Kalyuzhnyy, A. Dmytruk, I. Blonskyi, Self-organized structuring of the surface of a metal–semiconductor composite by femtosecond laser processing. Ukr. J. Phys. 63, 406–412 (2018). https://doi.org/10.15407/ujpe63.5.40610.15407/ujpe63.5.406 ↗
32. S. Lei, X. Zhao, X. Yu, A. Hu, S. Vukelic, M.B.G. Jun, H.E. Joe, Y. Lawrence. Yao, Y.C. Shin, Ultrafast laser applications in manufacturing processes: a state-of-the-art review. J. Manuf. Sci. Eng. (2020). https://doi.org/10.1115/1.404596910.1115/1.4045969 ↗
33. L. Wang, K. Yin, X. Li, Y. Huang, J. Xiao, J. Pei, X. Song, J. Duan, C.J. Arnusch, Femtosecond laser ultrafast atomic scale renovating laser-Induced graphene. Adv. Funct. Mater. 2506215, 1–12 (2025). https://doi.org/10.1002/adfm.20250621510.1002/adfm.202506215 ↗
34. K. Yin, D. Chu, X. Dong, C. Wang, J. Duan, J. He, Femtosecond laser induced robust periodic nanoripple structured mesh for highly efficient oil–water separation. Nanoscale. 9, 14229–14235 (2017). https://doi.org/10.1039/C7NR04582D10.1039/C7NR04582D ↗
35. L. Wang, K. Yin, Q. Deng, Q. Huang, J. He, J. Duan, Wetting Ridge-Guided directional water Self‐Transport. Adv. Sci. 9, 1–10 (2022). https://doi.org/10.1002/advs.20220489110.1002/advs.202204891 ↗
36. M. Du, Q. Sun, W. Jiao, L. Shen, X. Chen, J. Xiao, J. Xu, Fabrication of antireflection micro/nanostructures on the surface of aluminum alloy by femtosecond laser. Micromachines (2021). https://doi.org/10.3390/mi1211140610.3390/mi12111406 ↗
37. G. Long, J. Duan, S. Zhou, C. Wang, J. Ke, J. Zhang, J. Xu, J. Xiao, Femtosecond laser processing for multi-functional hierarchical micro/nano structures on curved surfaces. Appl. Surf. Sci. 684, 161850 (2025). https://doi.org/10.1016/j.apsusc.2024.16185010.1016/j.apsusc.2024.161850 ↗
38. J. Li, M. Du, Q. Sun, F. Yi, Analysis of anti-reflection mechanisms of the black aluminum alloy made by femtosecond laser processing. Mater. Res. Express (2022). https://doi.org/10.1088/2053-1591/aca8e910.1088/2053-1591/aca8e9 ↗