Control of pit initiation sites on aluminum foil using colloidal crystals as mask

The electrochemical etching of aluminum foils using a physical mask of colloidal spheres was studied to directly control the initiation sites of pits independent of the surface activation state of the substrate. A two-dimensional array of colloidal spheres used as a mask was prepared by self-assembly on an aluminum substrate. The transfer of the hexagonally ordered pattern of self-assembled colloidal spheres to the aluminum substrate could be achieved by the selective electrochemical etching of an exposed aluminum surface. That is, etch pits were generated only in the triangular void space among the three spheres on the aluminum surface. Based on this process, the dispersibility of the initiation sites of pits was improved clearly in comparison with that for the conventional method. The density of pits could also be controlled by changing the diameter of spheres used as a mask.