Investigations on Corrosion and Cavitation Erosion Resistance of Superhydrophobic PTFE‐Coated AA5083 Alloy

Aluminum‐based alloys, particularly AA5083, are widely used in naval and marine applications due to their excellent corrosion resistance. However, in chloride‐rich environments, these alloys are prone to localized corrosion, which can affect the durability of these materials. This study addresses particular challenges by implementing an effective method to fabricate superhydrophobic surfaces (SHS) on AA5083 alloys, with the help of laser surface texturing and polytetrafluoroethylene (PTFE) spray coating. Elliptical patterns created through fiber laser marking significantly enhance the adhesion between the PTFE coating and the substrate. The presence of carbon and fluorine in PTFE reduces surface energy, resulting in a SHS with a water contact angle (WCA) of 155.7°. Corrosion resistance is evaluated using salt spray testing, demonstrating substantial improvement compared to uncoated specimens. Additionally, the PTFE coating plays a crucial role in enhancing cavitation erosion resistance, while surface texturing contributes to improved creep indentation resistance. The mechanical stability and adhesion of the coating are assessed through ultrasonic cavitation and tape‐peeling tests, respectively. Even after ten tape‐peel cycles, the surface retains its hydrophobicity with a WCA of 139°. This study highlights the potential of laser‐textured, PTFE‐coated AA5083 alloy for the marine environment, a promising approach to enhance corrosion resistance.