Mechanically and Boiling Water Stable Superhydrophobic Coatings with Special Composite Structures Prepared by Facile Spraying Method

Obtaining mechanical stability and environmental durability is a key but challenging issue in the development of superhydrophobic coatings. Here, a superhydrophobic coating with high mechanical stability and environmental durability was fabricated through layer-by-layer spraying the silicone/epoxy resin composite and micro-nanoparticles. By layer-by-layer spraying, the resins and the micro-nanoparticle could be modulated separately. The use of the silicone/epoxy resin composite not only adjusts the hardness of the coating, but also allows the fabrication of special composite structures consisting of resin framework and particle clusters by adjusting the solubility between the resin material and the solvent of the micro-nano particles’ solution. Based on the high hardness and special composite microstructure, the superhydrophobic coatings exhibit high mechanical stability (abrasion 45   m under a load of 200   g) and environmental robustness (boiling water immersion for 24   h). The particle clusters can continuously replenish the micro-nano-particles lost during the surface abrasion, thus prolonging the coating’s service life. In addition, the coatings possessed an ultra-high corrosion inhibition efficiency of 99.99% and drag reduction effect (2~21% at the velocity of 2~5.75   m/s). The presented work provides valuable insights into the design and fabrication of highly stable superhydrophobic coatings.