Highly resistant icephobic coatings on aluminum alloys

Abstract Aluminum alloys are widely used for outdoor structures such as ground wires and phase conductors of overhead power lines, as well as aircrafts wings and fuselage. To protect these surfaces against excessive ice accumulation, icephobic coatings must be highly reliable and durable. New coatings with icephobic characteristics and excellent mechanical properties have been developed. The method consisted in depositing an extremely adherent poly(tetrafluoroethylene) (PTFE) coating on an Al2O3 underlayer produced by anodizing in a phosphoric acid electrolyte followed by an oxide etching step to enhance surface roughness. PTFE impregnation was carried out at low temperature (320 °C) and coating adhesion was assessed using tape and bend tests. Some of these coatings showed superhydrophobic properties; ice adhesion was around four times lower than bare aluminum. As well, they remained effective after ten ice-shedding events using an aggressive centrifugal technique. Moreover, no sign of PTFE degradation after 14 ice removals was noted and the coatings remained extremely adherent and very hydrophobic. This technique therefore shows very good potential and could be applied to new high-voltage overhead aluminum cables as protection against excessive ice or snow accumulation.