Silicon surface hydrophobicity has been varied by using silane treatments on silicon pyramid surfaces generated by KOH anisotropic etching. Results demonstrated that by altering the surface hydrophobicity, the apparent contact angle changed in accord with the Wenzel equation for surface structures with inclined side walls. Hierarchical structures were also constructed from Si pyramids where nanostructures were added by Au-assisted electroless HF/H2O2 etching. Surface hydrophobicity and superhydrophobicity were achieved by surface modification with a variety of silanes. Stability of the Cassie state of superhydrophobicity is described with respect to the Laplace pressure as indicated by the water droplet meniscus in contact with the hierarchical structures. The contact angle hysteresis observed is also discussed with respect to water/substrate adhesion.

Improvement of the robustness of superhydrophobic surfaces is critical in order to achieve commercial applications of these surfaces in such diverse areas as self-cleaning, water repellency and corrosion resistance. In this study, the mechanical robustness of superhydrophobic surfaces was evaluated on hierarchically structured silicon surfaces. The effect of two-scale hierarchical structures on robustness was investigated using an abrasion test and the results compared to those of superhydrophobic surfaces fabricated from polymeric materials and from silicon that contains only nanostructures. Unlike the polymeric and nanostructure-only surfaces, the hierarchical structures retained superhydrophobic behavior after mechanical abrasion.

Considerable effort has been expended on theoretical studies of superhydrophobic surfaces with two-tier (micro and nano) roughness, but experimental studies are few due to the difficulties in fabricating such surfaces in a controllable way. The objective of this work is to experimentally study the wetting and hydrophobicity of water droplets on two-tier rough surfaces for comparison with theoretical analyses. To compare wetting on micropatterned silicon surfaces with wetting on nanoscale roughness surfaces, two model systems are fabricated: carbon nanotube arrays on silicon wafers and carbon nanotube arrays on carbon nanotube films. All surfaces are coated with 20 nm thick fluorocarbon films to obtain low surface energies. The results show that the microstructural characteristics must be optimized to achieve stable superhydrophobicity on microscale rough surfaces. However, the presence of nanoscale roughness allows a much broader range of surface design criteria, decreases the contact angle hysteresis to less than 1 degrees , and establishes stable and robust superhydrophobicity, although nanoscale roughness could not increase the apparent contact angle significantly if the microscale roughness dominates.

Low contact angle hysteresis is an important characteristic of superhydrophobic surfaces for nonstick applications involving the exposure of these surfaces to water or dust particles. In this article, a relationship is derived between the surface work of adhesion and the dynamic contact angle hysteresis, and the resulting predictions are compared with experimental data. Superhydrophobic surfaces with different contact angles and contact angle hysteresis were prepared by generating silicon pillars with varying pillar size and pitch. Surfaces were subsequently treated with fluoroalkyl silanes to modify further the hydrophobicity. The threephase contact line established for such systems was related to the Laplace pressure needed to maintain a stable superhydrophobic state.

Surfaces of hexagonally packed silica spheres have been functionalized with silanes containing different hydrocarbon or fluorocarbon chains. The resulting chemical and physical structures were studied to establish the effect of surface hydrophobicity on the measured contact angles on the rough surfaces. The results were used to assess the effects of surface modifications on the parameters in the Cassie equation. To achieve superhydrophobicity via a biomimetic approach, we created two-scale structures by first forming hexagonally packed SiO2 spheres, followed by Au deposition on the spheres and heat treatment to form Au nanoparticles on sphere surfaces. Contact angles over 160 degrees were achieved. This work provides improved understanding of the effect of the surface roughness and solid surface fraction on superhydrophobicity.