Energy-Efficient Anti-Icing and De-Icing of TC4 Titanium Alloy Surfaces Enabled by Laser-Patterned Microstructures and Electrothermal Heating

Surface icing poses a significant risk to unmanned aerial vehicles (UAVs) and compact aerospace platforms, where limited onboard power and space require efficient anti-/de-icing surfaces. In this study, micro/nanostructures were fabricated on TC4 titanium alloy (Ti–6Al–4V) surfaces by femtosecond laser processing at different scanning speeds. The effects of scanning speed on surface morphology, wettability, static freezing, dynamic droplet behavior, and electrothermal de-icing performance were systematically investigated. Increasing the scanning speed induced nonlinear changes in microstructure height and surface roughness, while variations in ablation intensity caused nonuniform material redistribution. The surface processed at 250 mm/s showed the best anti-icing performance, with a water contact angle of 157.5 ± 0.5° and a maximum freezing delay 21.5 times longer than untreated TC4. During electrothermal de-icing, melting initiated at discrete ice–substrate contact points, forming coalesced meltwater films, while interfacial stress concentration promoted crack propagation and rapid ice detachment. Compared with untreated surfaces, ice detachment time (250 mm/s) achieved complete ice detachment at approximately 152 s, whereas ice on the untreated surface remained adhered after 270 s of continuous heating, representing a de-icing time reduction of at least 44%. These results demonstrate that combining laser-fabricated microstructures with electrothermal heating effectively reduces real ice–substrate contact, providing an enhanced anti-/de-icing strategy for lightweight, long-endurance UAV applications under identical electrical input.