Self-organized pattern formation on silicon, stainless steel and zinc coated steel substrates

•Stainless steel and zinc coated steel are novel substrates in the self-organization study.•Polystyrene MW influences the dimensions of the forming patterns.•Substrate material controls the self-organized pattern formation.

In this research, a self-organized pattern formation employing polystyrene/aluminum bilayer coatings on three different substrates was studied. Two new substrate materials, stainless steel and zinc coated steel for self-organization application were introduced. Influence of polystyrene molar mass on pattern formation was studied with five different polystyrene samples having molar masses between 27 and 247 × 103 g/mol. Polystyrene/toluene solutions were applied onto the substrates using the spin coating technique and aluminum layer was created by chemical vapor deposition (CVD). Self-organized pattern formation was induced thermally, by heating the layered substrate/polystyrene/aluminum structures above the glass transition temperature of polystyrene. Sub-micron–micron sized wrinkles or island-like surface patterns were achieved on all substrates. The molar mass of polystyrene was found to have effect on the dimensions of the formed structures. It was also observed that the characteristic surface structure of substrates influences self-organization and thereby directs the structure formation.