Ice accretion can adversely impact many engineering structures in commercial and residential sectors. Although there are many reports of low-ice-adhesion-strength materials, a scalable and durable deicing solution remains elusive, as ice detachment is dominated by interfacial toughness for large interfaces. In this work, durable metallic coatings based on Al-rich quasicrystalline alloys were prepared and applied on aluminum substrates using high-velocity oxyfuel thermal spray. X-ray diffraction patterns confirmed the quasicrystalline phases of the coating, and its large-scale deicing capability was studied by evaluating the coating's ice detachment mechanics using long lengths of ice. A toughness-controlled regime of interfacial fracture was observed for ice lengths longer than ∼2 cm, and a low shear strength of ∼30 kPa was achieved for a 20 cm ice length. The metallic coatings exhibited excellent ice repellency even after being abraded, scratched, heated, UV-irradiated, and exposed to chemical contaminations, demonstrating promising durability for real-world, large-scale ice removal.
Keywords: deicing; high-velocity oxyfuel thermal spray; ice-phobic; interfacial toughness; quasicrystals.