Protection of carbon steel with superhydrophobic coating against corrosion in NaCl solution

Facile and Eco-Friendly Preparation of Mild Steel Based Superhydrophobic Surfaces without Chemical Modifications

The fabrication of superhydrophobic coatings on mild steel has attracted considerable attention. However, some methods are cumbersome and unsuitable for large-scale preparation, limiting industrial applications. Furthermore, the extensive use of fluorinated compounds to achieve low surface energy is not environmentally friendly. This paper proposed a facile method based on electrodeposition and annealing to prepare mild steel-based superhydrophobic surfaces without chemical modifications. Subsequently, SEM images were analyzed, and it was observed that the plating parameter (current and time) significantly affected surface morphology. At optimum process parameters, a rough surface with a multi-level structure was formed on the plated surface, contributing to superhydrophobic properties. XPS, EDS, and XRD were utilized to analyze surface composition. The results indicated the presence of copper oxides, zinc oxides, and a large number of hydrocarbons on the prepared superhydrophobic surface. These transition metal oxides on the surface adsorbed hydrocarbons in the air during the annealing process, which lowered the surface energy. Combined with the obtained multi-level morphology, a superhydrophobic surface was achieved. Finally, the corrosion behavior was evaluated in 3.5 wt% NaCl solution by AC impedance spectroscopy. Results showed that the obtained superhydrophobic surface, compared with the untreated coating and the steel substrate, showed a substantial improvement in corrosion resistance. A mild steel-based superhydrophobic surface with a contact angle greater than 150 degrees and excellent corrosion resistance was finally obtained. We hope this study will facilitate the industrial preparation of superhydrophobic coatings, especially in marine engineering, since this method does not require complex processes or expensive equipment and does not require fluorinated substances.