Micro- and nanostructure formation on duralumin by femtosecond laser processing for optical camouflage and diverse industrial applications

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.