Enhanced corrosion resistance of 2024-T351 aluminum alloy through high-speed laser texturing using a polygon scanner

Corrosion accounts for approximately 3 % of the global GDP annually, primarily due to degradation in metallic materials such as aluminum and steel. This study explores high-speed direct laser writing (DLW) using a polygon scanner combined with an ultrafast picosecond laser source to enhance corrosion resistance of aluminum surfaces. Laser structuring was performed on aluminum 2024-T351, a low-corrosion-resistant alloy, applying laser fluences up to 8.7 J/cm². Surface analyses revealed periodic as well as random nanostructures with structure depths up to 40 µm ± 5.3 µm. Wettability analysis showed only a moderate increase in water contact angles (WCAs) to 110° ± 6°, which is insufficient for superhydrophobic behavior. However, the corrosion performance, assessed through potentiodynamic curves, demonstrated a reduction in corrosion rates from 19.1 to 1.45 µm/year, achieving an inhibition efficiency of 93 %.