An aluminum substrate is provided with a superhydrophobic surface structure that comprises a porous alumina layer having a hydrophobic coating. The porous alumina layer is created on the aluminum substrate by an anodizing process, and is engineered such that the thickness of the alumina layer and the diameters of the pores have nanoscale values. The anodizing process is performed in two anodizing steps with an intermediate etching step. The superhydrophobic surface provides protection against corrosion by entrapping air in the pores so as to prevent penetration of water to the aluminum metal.

Full Patent: Nanoengineered superhydrophobic anti-corrosive aluminum surfaces