# Achieving Large-Area Hot Embossing of Anti-Icing Functional Microstructures Based on a Multi-Arc Ion-Plating Mold

## TL;DR

This paper presents a new method for creating anti-icing microstructures on aluminum surfaces using a multi-arc ion-plating mold, improving embossing quality and performance.

## Contribution

A novel PVD-coated mold for hot embossing that enhances filling quality and anti-icing properties of microstructures.

## Key findings

- PVD-coated steel shows 44.7% higher hardness and 66.2% lower friction coefficient than conventional steel.
- PVD-coated punch-assisted embossing at 300°C ensures complete filling of micro-array channels without defects.
- Micro-array channels reduced freezing fraction by 53.2% and delayed freezing time by 193.3% due to trapped air layers.

## Abstract

Aluminum alloy surface microstructures possess functional characteristics such as hydrophilicity/hydrophobicity and anti-icing and have important applications in fields such as aerospace and power systems. In order to improve the filling quality of the microstructure and verify the anti-icing property of the microstructure, this work develops a scheme for achieving large-area hot embossing of anti-icing functional microstructures based on a multi-arc ion-plating mold. Compared with conventional steel, the hardness of the PVD-coated steel increases by 44.7%, the friction coefficient decreases by 66.2%, and the wear resistance is significantly enhanced. The PVD-coated punch-assisted embossing could significantly improve filling properties. While the embossing temperature is 300 °C, the PVD-coated punch-assisted embossing can ensure the complete filling of the micro-array channels. In contrast, under-filling defects occur in conventional hot embossing. Then, a large-area micro-channel specimen of 100 cm2 was precisely formed without warping, and the average surface roughness Ra was better than 0.8 µm. The maximum freezing fraction of the micro-array channel was reduced by about 53.2% compared with the planar, and the complete freezing time was delayed by 193.3%. The main reason is that the air layer trapped by the hydrophobic structures hinders heat loss at the solid–liquid interface.