Using both artificial and natural templates, biomimetic micro-structures are fabricated on conventional coating materials (epoxy and silicone elastomers) to mimic both artificial and natural templates through effective pattern transfer processes. The pattern transfer processes use a soft-polymer negative stamp, where the flexibility of the stamp allows for easy conformation to both flat and curved surfaces. Patterns have been successfully transferred as a rigid epoxy to complex surfaces or as a soft elastomer replica of a hydrophobic Trembling Aspen leaf. The hydrophobicity and friction behaviour of the resulting micro-patterned surfaces are systematically investigated, showing that surface patterning can be used as an effective way to improve hydrophobicity while reducing the surface adhesion and friction without a loss of the structural integrity or rigidity typical of epoxy coatings. The relative strength of the micro-pattern was determined through indentation testing in order to support the claim of a robust pattern on the micro-scale that is able to withstand the harsh environment of industrial application or weather exposure. With the well characterized patterned epoxy material fabricated and able to be transferred to many different surfaces, the potential for the patterned surface to act as an icephobic coating was pursued. The robustness of the epoxy material with the unique ability to coat surfaces that are typically unable to possess a micro-structure makes this coating an ideal candidate for large-scale icephobic application. The potential use of a micro-patterned epoxy coating is investigated against comparable surface coatings within an innovative experimental set-up to measure the relative ice-adhesion strength of different substrates. In characterizing the relative shear-force required to remove frozen water droplets from the coating surface at the interface, several variables and factors were explored. The addition of a surface pattern was found to impact the icephobic ability of several materials, where different materials with the same pattern were compared to identify that the surface energy of the substrate influences the icephobic nature of a surface. Moreover, previous studies that relate the water contact angle or hysteresis to ice-adhesion strength are questioned through a preliminary qualitative analysis of ice adhesion strength data. This work demonstrates a potential process for the utilization of biomimetic epoxy micro-patterns as an enhanced hydrophobic and icephobic option for large scale protective coatings.

<p>Development of durable icephobic coating and reduction of ice accumulation on the product surfaces has proven to be a challenging task in the past decade. Considering the challenges posted during ice storms and existing limitations to the state of the art, development of durable icephobic coating which can provide low ice adhesion strength and less ice weight increase is a critical milestone for industries and research communities. To obtain durable icephobic coating, high temperature and weather resistance Fluoro-Ethylene-Alkyl-Vinyl-Ether (FEVE) binder was selected to design a smooth and superhydrophobic coatings. These coatings were benchmarked against commercially available silicone epoxy and superhydrophobic coatings and validated its surface roughness, surface wettability and icephobic performance such as ice adhesion strength and ice accumulation. To evaluate coatings thermal durability, targeting power transmission line application, these coatings were exposed to extreme thermal ageing conditions (200 ^oC for 60 days) and retention of icephobic performance were measured. Though, commercial coatings have provided better icephobicity at unaged condition, after high temperature heat ageing these coatings icephobic performance were deteriorated significantly. However, FEVE based coating had retained its surface characteristics and icephobic properties after aggressive thermal ageing.</p>

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Ice buildup on structures leads to problems that include reduced performance, structural damage and power outages. It is therefore important to limit the energy required for removal of ice from substrates to minimize buildup. Understanding the mechanism of ice adhesion and its dependence on variables like coating thickness, stiffness, surface free energy and morphology is critical for minimizing adhesion. Despite several developments in “icephobic” coatings, which are those that have low ice adhesion, it is important to understand adhesion on the fundamental level to make way for advanced coatings. To do so, a study has been carried out that explores key variables affecting ice adhesion using a commercially available silicone, Sylgard 184®. Sylgard 184 is a two-part, platinum cured silicone elastomer available from Dow Corning with good physical and chemical stability and is used in widely diverse research studies. The thermodynamic work of ice adhesion is related to the receding contact angle θ_r of water by Equation 1. wa≈ γ_w (1+cos⁡ θ_r) Eq 1. where γ_w is the surface tension of water. Considering an elastomeric substrate and ice as a rigid cylindrical adherent, the Kendall modelcan be adapted to relate peak removal force (Pc) with work of adhesion (wa), modulus (K), thickness (t), and radius (a) according to Equation 2. Pc ∝ πa^2 ((2wa K)/t)^(1⁄2) Eq. 2 Considering these relationships, hydrophobic materials with low surface energies and high receding contact angles are generally predicted to show low adhesion. To begin to understand details, the force required to remove an ice cylinder from the silicone elastomer Sylgard 184 was investigated by focusing on three variables: coating thickness, modulus and cure temperature. “Cure” refers to the network formation or crosslinking within the material. The Wynne research group has previously established a surprising dependence of qR on Sylgard 184 cure temperature.In this thesis, the relationship among variables noted above was examined by measuring Pc for Sylgard coatings. Additionally, effects of test temperature on ice adhesion strength was studied. Surface characterization methods including ATR-IR (attenuated total reflectance infrared spectroscopy), DCA (Wilhelmy plate dynamic contact angles) and AFM (atomic force microscopy) were employed. In summary, defined processing conditions were found optimum for minimizing ice adhesion to Sylgard coatings.