In the present study, a simple, scalable, and cost-effective approach is proposed, integrating thermo-mechanical and microwave-assisted hydrothermal processing techniques. The strategic infusion of dopants (Mg, Zn, Fe, Co, Si) during thermo-mechanical processing significantly enhanced the formation of distinct, dense nanostructures on metallic surfaces, surpassing the complexities of traditional systems. These dopants played a pivotal role in tailoring surface morphology, resulting in remarkable de-wetting behavior post silanization. The fabricated surfaces exhibited high contact angle ( \({\theta }_{s}\) > 155°) with a low tilt angle ( \({\theta }_{t}\) < 10°) and CAH (< 5°). The doped samples demonstrated notably reduced adhesion forces (< 15 µN) compared to untreated counterparts (> 50 µN), attributed to their intricate nanostructured morphology and enhanced air entrapment in the Cassie state ( \({E}_{C-B}>1.0 J\) ). Furthermore, the highly dense network of nanostructures induced strong negative capillary pressures ( \({P}_{C}\) > 1100 kPa) reinforcing the de-wetting characteristics and mechanical resilience of the surfaces. This resilience was evident in abrasion tests, simulated rain, and long-term immersion experiments, where doped samples consistently maintained low tilt angles ( \({\theta }_{t}\) < 10°) and CAH (< 5°) stabilizing Cassie state and restricting three-phase line sagging. The present work highlights the importance of doping in enhancing the durability of nanostructures for improving de-wettability.
