Laser texturing of AA2024 alloy: A simplified approach to improve corrosion resistance and achieve superhydrophobicity

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Despite its susceptibility to corrosion, AA2024 alloy is extensively used in the aerospace industry due to its favourable mechanical properties. Conventional corrosion protection methods frequently rely on hazardous chemicals and complex multi-step processes, which limits their sustainability and scalability. This study focuses on the development of an environmentally friendly, simplified laser-based method that structures surfaces in a single scan, producing line-like microstructures that achieve superhydrophobicity. The surfaces present static water contact angles of up to 160° and roll-off angles below 5°. The laser treatment results in the creation of a thicker Al 2 O 3 oxide layer on the surfaces, as evidenced by FIB-STEM images and the chemical characterization through XPS analysis. Consequently, the treated surfaces exhibit a notable enhancement in polarization resistance, rising from 23.6 kΩ cm 2 to 159.5 kΩ cm 2 . This study provides insights into the viability of a novel, simple, laser-based approach for corrosion protection that exhibits additional wetting properties. • A simplified laser-method created line-like microstructures with a single step process. • The FIB-STEM analysis indicated a six-fold increase in the thickness of the oxide layer in AA2024. • Laser treatment increased Al₂O₃ content from 2.3 % to 12.1 %, reducing Al(OH)₃. • Treated surfaces achieved superhydrophobicity with WCA > 150° and roll-off angles below 5°. • The polarization resistance was increased from 23.6 kΩ cm 2 to 159.5 kΩ cm 2 .