On the Durability and Wear Resistance of Transparent Superhydrophobic Coatings

Transition of Liquid Drops on Microstructured Hygrophobic Surfaces from the Impaled Wenzel State to the "Fakir" Cassie-Baxter State

Low adhesion of liquids on solid surfaces can be achieved with protrusions that minimize the contact area between the liquid and the solid. The wetting state where an air cushion forms under the drop is known as the Cassie-Baxter state. Surfaces where liquids form macroscopic contact angles above 150° are called superhydrophobic and superhygrophobic, if we refer to water or any liquid, respectively. The Cassie state is desirable for applications, but it is usually unstable compared to the Wenzel state, where the drop is in direct contact with the rough surface. The Cassie-to-Wenzel transition can be triggered by an increase in pressure and vibrations, but the inverse Wenzel-to-Cassie is much more difficult to observe. Here, we examine under what conditions the Wenzel-to-Cassie transition is triggered when the microscopic contact angle changes abruptly. For this, we applied a lubricant of low surface tension around drops that were in the Wenzel state on microstructured surfaces. The increase of the microscopic contact angle lifted the drop from the rough surface, when the pillar height and spacing are large and small, respectively. Numerical calculations for the drop-lubricant interface showed that the surface geometry requirements for the Wenzel-to-Cassie transition are stricter than the ones for the stability of the Cassie state. A surface geometry where the Cassie state is more stable than the Wenzel for a given Laplace pressure of the drop may not always allow the Wenzel-to-Cassie transition to take place. Therefore, the stability of the Cassie state is a necessary but insufficient condition for the inverse transition.

Engineering an Almost All-Waterborne System for Transparent yet Superhydrophobic Surfaces with High Liquid Impalement Resistance

Realistically, green manufacturing of transparent superhydrophobic surfaces (SHSs) and high liquid impalement resistance for outdoor engineering are very necessary but pretty challenging. To address this, an almost all-waterborne system composed of synthesized partially open-cage fluorinated polyhedral oligomeric silsesquioxane bearing a pair of -OH (poc-FPOSS-2OH), silica sol, and resin precursor is engineered. The transparent SHSs facilely formed by this system are featured with the exclusive presence of wrapped silica nanoparticle (SiNP) dendritic networks at solid-gas interfaces. The wrapped SiNP dendritic networks have a small aggregation size and low distribution depth, making SHSs highly transparent. The Si-O polymeric wrappers render mechanical flexibility to SiNP dendritic networks and thus enable transparent SHSs to resist high-speed water jet impinging with a Weber number of ≥19 800 in conjunction with the extremely low-surface-energy poc-FPOSS-2OH, which is the highest liquid impalement resistance so far among waterborne SHSs, and can rival the state-of-the-art solventborne SHSs.

Modifying flexible polymer films towards superhydrophobicity and superoleophobicity by utilizing water-based nanohybrid coatings

The development of superhydrophobic and/or superoleophobic materials has been attracting the attention of the scientific community due to their wide range of applications. In this work, waterborne nanocomposite coatings were developed to be deposited onto flexible polyethylene films in order to modify them into superhydrophobic and even superoleophobic. The coatings consisted of either a low surface energy mixture of silanes/siloxanes or a fluoropolymer in conjunction with the appropriate inorganic nanoparticles that provide the necessary roughness; the effects of nanoparticle type and content on the behaviour was investigated. In both cases, the surface properties were investigated, and the polymer films were found to be superhydrophobic. Depending on the system utilized, the final material exhibited either low water adhesion, thus, being water repellent, or high water adhesion. The use of the fluoropolymer has led to coatings that exhibited superoleophobic behaviour for various organic compounds, as well. The application of the coatings did not influence either the optical transparency or the thermal properties of the polyethylene films. Moreover, the coated surfaces show similar or even better mechanical properties, scratch resistance and chemical durability in comparison to the neat LDPE film.

A wear and heat-resistant hydrophobic fluoride-free coating based on modified nanoparticles and waterborne-modified polyacrylic resin

Hydrophobic coatings have attracted extensive research due to their broad application prospects. However, hydrophobic coatings in practical applications are often limited by their insufficient stability and are difficult to be applied on a large scale. In this regard, wear and heat resistance are key aspects that must be considered. In this paper, a method for preparing a robust hydrophobic coating with modified ZrO₂ particles as the core component and modified acrylic resin is proposed. First, γ-aminopropyltriethoxysilane (APTES) was used to silanize ZrO₂ to obtain Si-ZrO₂ nanoparticles, which were grafted with amino groups. Then, the nanoparticles reacted with isocyanates to be grafted with hydrophobic groups. A simple spray method was developed to deposit a hydrophobic (141.8°) coating using the mixture containing the modified nanoparticles and non-fluorinated water-based silicon-modified acrylic resin (WSAR) that was prepared by free radical polymerization. The obtained coating exhibited a rough surface and the particles and resin were closely combined. Compared with pure resin coating, the composite coating exhibited 150% enhancement in wear resistance and it could wear 45 meters at a pressure of 20 kPa. Moreover, the coating could maintain the hydrophobic property even when it lost 70% quality or after it was heated at 390 °C. The thermogravimetric results showed that the temperature could reach 400 °C before the quality of the fluorine-free coating dropped to 90%. In addition, the coating could easily take away graphite or silicon carbide powder under the impact of water droplets, showing excellent self-cleaning performance.

Anti-mold, self-cleaning superhydrophobic bamboo fiber/polypropylene composites with mechanical durability

Bamboo fiber/polypropylene composites (BPCs) have been widely used in buildings, interior decoration, and automobile components. However, pollutants and fungi can interact with the hydrophilic bamboo fibers on the surface of Bamboo fiber/polypropylene composites, degrading their appearance and mechanical properties. To improve their anti-fouling and anti-mildew properties, a superhydrophobic modified Bamboo fiber/polypropylene composite (BPC-TiO₂-F) was fabricated by introducing titanium dioxide (TiO₂) and poly(DOPAm-co-PFOEA) onto the surface of a Bamboo fiber/polypropylene composite. The morphology of BPC-TiO₂-F was analyzed by XPS, FTIR, and SEM. The results showed that TiO₂ particles covered on Bamboo fiber/polypropylene composite surface via complexation between phenolic hydroxyl groups and Ti atoms. Low-surface-energy fluorine-containing poly(DOPAm-co-PFOEA) was introduced onto the Bamboo fiber/polypropylene composite surface, forming a rough micro/nanostructure that endowed BPC-TiO₂-F with superhydrophobicity (water contact angle = 151.0° ± 0.5°). The modified Bamboo fiber/polypropylene composite exhibited excellent self-cleaning properties, and a model contaminant, Fe₃O₄ powder, was rapidly removed from the surface by water drops. BPC-TiO₂-F showed excellent anti-mold performance, and no mold was on its surface after 28 days. The superhydrophobic BPC-TiO₂-F had good mechanical durability and could withstand sandpaper abrasion with a weight load of 50 g, finger wiping for 20 cycles, and tape adhesion abrasion for 40 cycles. BPC-TiO₂-F showed good self-cleaning properties, mildew resistance, and mechanical resistance, giving it promising applications for automotive upholstery and building decoration.

Achieving Superhydrophobic Surfaces via Air-Assisted Electrospray

Superhydrophobic surface is an enabling technology in numerous emerging and practical applications such as self-cleaning, anticorrosion, antifouling, anti-icing coatings, and oil-water separation. Here, we report a facile air-assisted electrospray approach to achieve a superhydrophobic surface by systematically studying spray conditions and the chemistry of a coating precursor solution consisting of silicon dioxide nanoparticles, polyacrylonitrile, and N,N-dimethylformamide. The wettability behavior of the surface was analyzed with contact angle measurement and correlated with surface structures. The superhydrophobic coating exhibits remarkable water and oil repellent characteristics, as well as good robustness against abrasion and harsh chemical conditions. This air-assisted electrospray technique has shown great control over the coating process and properties and thus can be potentially used for various advanced industrial applications for self-cleaning and anticorrosion surfaces.

Robust and durable liquid-repellent surfaces

This review provides a comprehensive summary of characterization, design, fabrication, and application of robust and durable liquid-repellent surfaces.

Transparent Self-Cleaning Coatings Based on Colorless Polyimide/Silica Sol Nanocomposite

We herein report transparent self-cleaning coatings based on polyimide-fluorinated silica sol (PIFSS) nanocomposite. Polyamic acid-silica sol (PASS) suspensions were synthesized by adding four different amounts of a silica sol suspension to each end-capped polyamic acid solution. The PASS suspensions were spin-coated on glass slides, thermally imidized and treated with triethoxy-1H,1H,2H,2H-perfluorodecylsilane (TEFDS) to prepare PIFSS coatings. The PIFSS coatings showed high resistance to separation from glass substrates and thermal stability. Furthermore, the PIFSS coatings on the glass substrate could be cleanly removed using polar aprotic solvents and repeated coating was possible. As the amount of silica sol particles in the PIFSS coating was increased, the hydrophobic contact angle increased. Among them, PIFSS-10 and PIFSS-15 coatings showed nearly superhydrophobic contact angles (144° and 148°, respectively) and good self-cleaning property. It was confirmed by SEM and AFM studies that their hydrophobic and self-cleaning properties are due to uniform particle distribution and relatively high surface roughness. PIFSS-10 coating showed a high transmittance value (88%) at 550 nm and good self-cleaning property, therefore suitable as a transparent self-cleaning coating. The advantages of the coating are that the fabrication process is simple, and the substrate is reusable. The PIFSS coating is expected to be applied in solar cell panels, windows, lenses and safety goggles.

Effects of Surface Morphology on Erosion–Corrosion and Corrosion Resistance of Highly Hydrophobic Nickel-Tungsten Electrodeposited Film

Hard nanocrystalline Ni-Co or Ni-W coatings are receiving a growing interest owing to their premium hardness, wear, and corrosion properties for several industrial applications. Furthermore, surface hydrophobicity greatly improves surface corrosion resistance. In this research, the durability of hydrophobic hierarchical NiW electrodeposited film has been evaluated in a high-speed slurry erosion–corrosion (EC) test rig. Two different coatings have been tested: a rough coating obtained in a chloride-based bath (NiWchloride) and a smooth coating obtained in a sulfate-based bath (NiWsulfate). Corrosion behavior over time was evaluated by electrochemical impedance spectroscopy (EIS), while surface hydrophobic performance was determined by the sessile drop method. The morphological features of the coatings were assessed by scanning electron microscopy while roughness modification during the EC tests were identified by means of an atomic force microscopy. During static immersion in the aggressive solution, the impedance modulus of the coatings continuously increased due to an increase in the thickness of corrosion products. During the EC test, the impedance modulus of the smooth NiW coating decreased, losing its barrier property. It was observed that the increase in impedance modulus of the hierarchical structure of the rough NiW coating during EC was far greater than that during static immersion. After 64 min of EC, the NiWchloride was able to resume its hydrophobicity property by storing in air; nevertheless, the NiWsulfate, with a loss of approximately 72% in its initial contact angle, was no longer hydrophobic. The results showed improvements in the lifetime of hydrophobic NiW coatings in erosion–corrosion conditions of the hierarchical nanostructure obtained in a chloride-based electroplating bath.

Transparent Super-Repellent Surfaces with Low Haze and High Jet Impact Resistance

Transparent superhydrophobic surfaces are of vital significance for rising applications in optoelectronics, outdoor displays, building windows, and so on. However, facile fabrication of surfaces combining stable superhydrophobicity and high transparency with particularly low haze remains a challenge. Here, we demonstrate a nonfluorinated hierarchical surface, simply prepared by sequential spraying of a primer of poly(ethylene-co-acrylic acid) (EAA) and silica nanoparticles (SiO₂). The resultant surface shows remarkable liquid repellency (e.g., an apparent contact angle of >160° and a sliding angle of <2° for honey) and high transparency (a transmittance of ∼91% and a haze of ∼6%). Especially, flexible EAA adhesive enables the surface to resist water impinging (up to ∼15.0 m s^-1, higher than the terminal velocities of raindrops) and mechanical damaging. This super-repellent surface also presents excellent UV and chemical stability, sustaining a superhydrophobic state upon UVA exposure for 60 days and acidic corrosion or oil contamination for 7 days. With multirobustness and scalability, our coatings show great potential in related fields.

Fabrication of TiO2-based broadband single-layer anti-reflection coating by collimated glancing angle deposition technique

Single-sided TiO2 thin films were prepared using a modified glancing angle deposition (GLAD) technique. An additional flux collimation plate was introduced into the GLAD arrangement to enhance the degree of collimation of depositing vapour flux. Enhancement in the ballistic growth of film on the substrate was observed with increasing distance from the vapour source. The substrate position near to the vapour source (i.e. bottom region) showed a high refractive index (RI, ∼1.336 @ 550 nm wavelength) and lower average film transmittance (∼94.5% in 400-900 nm wavelength range) compared to the others. In contrast, the TiO2 coating deposited at a distant position from the source (i.e. top region) showed a remarkably low RI (∼1.190 @ 550 nm wavelength) and excellent anti-reflection over a broad spectral region with a maximum average transmittance (∼95.3% in 400-900 nm wavelength) compared to the other substrate positions. The reduction in film RI was correlated qualitatively with the morphological alterations in the coating for different substrate positions. With a further increase in distance from the vapour source, an ultimate reduction in the RI of TiO2 to ∼1.101 was observed, which was ∼50% lower than the bulk TiO2 value (∼2.221 @ 550 nm wavelength). The present study reports the lowest RI of TiO2 together with fabrication of a TiO2-based broadband single-layer anti-reflection coating.

Hard yet Flexible Transparent Omniphobic GPOSS Coatings Modified with Perfluorinated Agents

Transparent materials with glasslike hardness and polymer-like flexibility are highly useful but rare. This paper reports the incorporation of the low-surface-tension pentafluoropropionic acid (FC₂-COOH) or tridecafluoroheptanoic acid (FC₆-COOH) into a 3-glycidyloxypropyl polyhedral oligomeric silsesquioxane (GPOSS) coating to yield hard/flexible omniphobic coatings. To avoid the macrophase separation of these additives from GPOSS and thus maintain the coating's high transparency, they are first reacted with excess GPOSS via the opening of the glycidyl rings with the carboxy groups to produce mixtures of GPOSS and GPOSS-FC₂ or GPOSS-FC₆. The fluorinated GPOSS mixtures are then photochemically cured. This study investigates the influence of the type and amount of a fluorinated agent used on the wetting and mechanical properties of the coatings. The wetting properties studied include surface energies, liquid sliding behavior, and repellency against an artificial fingerprint liquid. Meanwhile, the mechanical properties include pencil hardness, Young's modulus, hardness, and resistance to abrasion by steel wool and cheesecloth. Aside from producing coatings that may serve as a viable alternative for the currently used hard/flexible coatings in foldable smartphones, this paper provides guidelines for producing coatings with further improved omniphobicity and wear resistance.

Robust superhydrophobicity: mechanisms and strategies

Superhydrophobic surfaces hold great prospects for extremely diverse applications owing to their water repellence property. The essential feature of superhydrophobicity is micro-/nano-scopic roughness to reserve a large portion of air under a liquid drop. However, the vulnerability of the delicate surface textures significantly impedes the practical applications of superhydrophobic surfaces. Robust superhydrophobicity is a must to meet the rigorous industrial requirements and standards for commercial products. In recent years, major advancements have been made in elucidating the mechanisms of wetting transitions, design strategies and fabrication techniques of superhydrophobicity. This review will first introduce the mechanisms of wetting transitions, including the thermodynamic stability of the Cassie state and its breakdown conditions. Then we highlight the development, current status and future prospects of robust superhydrophobicity, including characterization, design strategies and fabrication techniques. In particular, design strategies, which are classified into passive resistance and active regeneration for the first time, are proposed and discussed extensively.

Challenges and Prospects of Bio-Inspired and Multifunctional Transparent Substrates and Barrier Layers for Optoelectronics

Bio-inspiration and advances in micro/nanomanufacturing processes have enabled the design and fabrication of micro/nanostructures on optoelectronic substrates and barrier layers to create a variety of functionalities. In this review article, we summarize research progress in multifunctional transparent substrates and barrier layers while discussing future challenges and prospects. We discuss different optoelectronic device configurations, sources of bio-inspiration, photon management properties, wetting properties, multifunctionality, functionality durability, and device durability, as well as choice of materials for optoelectronic substrates and barrier layers. These engineered surfaces may be used for various optoelectronic devices such as touch panels, solar modules, displays, and mobile devices in traditional rigid forms as well as emerging flexible versions.

Fluorine-Free Transparent Superhydrophobic Nanocomposite Coatings from Mesoporous Silica

In recent decades, there has been a growing interest in the development of functional, fluorine-free superhydrophobic surfaces with improved adhesion for better applicability into real-world problems. Here, we compare two different methods, spin coating and aerosol-assisted chemical vapor deposition (AACVD), for the synthesis of transparent fluorine-free superhydrophobic coatings. The material was made from a nanocomposite of (3-aminopropyl)triethoxysilane (APTES) functional mesoporous silica nanoparticles and titanium cross-linked polydimethylsiloxane with particle concentrations between 9 to 50 wt %. The silane that was used to lower the surface energy consisted of a long hydrocarbon chain without fluorine groups to reduce the environmental impact of the composite coating. Both spin coating and AACVD resulted in the formation of superhydrophobic surfaces with advancing contact angles up to 168°, a hysteresis of 3°, and a transparency of 90% at 550 nm. AACVD has proven to produce more uniform coatings with concentrations as low as 9 wt %, reaching superhydrophobicity. The metal oxide cross-linking improves the adhesion of the coating to the glass. Overall, AACVD was the more optimal method to prepare superhydrophobic coatings compared to spin coating due to higher contact angles, adhesion, and scalability of the fabrication process.

Spray-On Nanocomposite Coatings: Wettability and Conductivity

Nanocomposite coatings, i.e., a combination of nanocompounds, and a polymer matrix together with suitable additives and solvents is a very versatile method for producing multifunctional coatings. Some of the most desired coating properties have a high repellency to liquids (e.g., superhydrophobic and/or superoleophobic) and electrical and thermal conductivities. From a practical perspective, coatings that can be sprayed are very suitable for large-scale production, conformity, and reduced time and cost. Carbon-based, metallic, and ceramic are the three groups of nanocompounds commonly used to formulate spray-on nanocomposite coatings. In this invited feature article, we discuss the applications, advantages, and challenges of using such nanocompounds to produce coatings with good water repellency or/and elevated electrical or/and thermal conductivities. We also discuss the role of additives and solvents briefly in relation to the properties of the coatings. Important spraying parameters, such as stand-off distance and its influence on the final coating properties, will also be examined. Our overall aim is to provide a guideline for the production of practical multifunctional nanocomposites utilizing carbon-based, metallic, or ceramic nanoparticles or nanofibers that covers both aspects of in-air wettability and conductivity under one umbrella.

A Mini Review on Superhydrophobic and Transparent Surfaces

In recent years, self-cleaning and transparent surfaces have been widely studied for application on smart windows, solar panels, camera lenses, and other optoelectronic devices. The self-cleaning properties can possibly extend the lifetime of these products and decrease, even eliminate, the requirement of chemical detergents and high labor costs of cleaning. It can also promote the overall efficiency of outdoor optoelectronic devices (e. g. solar cell panels) since dirt accumulation and bacteria growth can be slowed down, even inhibited on such surfaces. In this mini review, the fundamentals and conditions that govern superhydrophobicity and transparency are introduced, followed by the discussion of roughness as the competing factor for superhydrophobicity and transparency. Representative examples of the surface design and fabrication are introduced and future perspectives are shared. This mini review can help the research community better understand such surfaces and further accelerate its development for innovative practical applications.

Flame Resistant Silicone-Containing Coating Materials

The flame resistance of applied coating materials affects the safety of innovative technological solutions. Silicone-containing polymeric materials are one of the most economical solutions in the field of coatings due to the effect of the unique combination of very good thermal, resistance, and surface properties. The rich chemistry of silicon compounds, which results in their very good thermal stability, allows their use as flame-resistant coating materials or as flame retardants in polymer composites. In this review, the flame resistance of PDMS systems based on their thermal degradation data, as well as possible paths of thermal degradation depending on external conditions including the effect of additives, flame resistance of hybrid silicone-containing coating materials and most important innovative applications of these materials, are reviewed. Very good results from the use of organic silicon compounds as fire retardants in polymers obtained by many research teams are one of the promising ways of overcoming the health, safety, and availability concerns of traditional halogenated fire retardants.

Molecular Aggregation Structure and Surface Properties of Biomimetic Catechol-Bearing Poly[2-(perfluorooctyl)ethyl acrylate] and Its Application to Superamphiphobic Coatings

The molecular aggregation structure and surface properties of a catechol-bearing fluoropolymer, P(FAC8-co-DOPAm), which was synthesized by conventional radical copolymerization of 2-(perfluorooctyl)ethyl acrylate (FAC8) and N-(3,4-dihydroxyphenethyl)acrylamide (DOPAm), and its application to the superamphiphobic surfaces are presented. The crystallinity of P(FAC8-co-DOPAm) was lower than that of poly[2-(perfluorooctyl)ethyl acrylate] (PFAC8). The perfluoroalkyl (Rf) groups were ordered on the surface with CF3 terminals exposed to air, and the Rf ordering was influenced by thermal history: the thermally annealed film exhibited higher Rf ordering than the unannealed one. The surface free energy was estimated to be γ = 7.32 mJ m-2 for both the unannealed and annealed films. Based on contact angle measurement, various interfacial structures of water and oils in accordance with the surface aggregation structure of Rf groups were proposed. Dewetting of the PFAC8 film at elevated temperature was suppressed by the introduction of catechol groups in the backbone. The degradation temperature of PFAC8 was improved significantly, and the evaporation of the low molar mass-polymer was inhibited by the introduction of catechol groups under both nitrogen and air atmospheres. The hydrophobicity of the copolymer films could be healed after the surface was damaged by vacuum ultraviolet (VUV) irradiation. This copolymer was used to create superamphiphobic fabrics and halloysite nanotube (HNT)-based organic/inorganic hybrid coatings successfully. Wetting behaviors of the superamphiphobic fabrics and coatings both follow the Cassie-Baxter wetting model.

Practical Applications of Superhydrophobic Materials and Coatings: Problems and Perspectives

Synthetic superhydrophobic (SH) surfaces were developed after 1990s, and the number of publications in this field is around 13 500 at present. However, the industrial production of SH coatings is very unsatisfying after the intensive research activity in the last two decades. The main reason is the loss of the water repellence properties when SH surfaces are exposed to outdoor conditions due to their weak mechanical properties and contamination from the medium which removes the initial SH properties. In this Feature Article, we focus on the scientific and technical reasons which prevent the application of the SH surfaces in our daily lives by highlighting some well-known but mostly overlooked problems in this area. (The synthesis methods of SH surfaces are not the subject of this article since they were reviewed previously in very good articles.) The basic contact angle science and the issue of the cancellation of the Wenzel and Cassie-Baxter equations are reviewed in the first part. The issues of the expensive and small-scale SH surface preparation problems, the difficulties in obtaining a transparent SH surface, the troubles arising from the water vapor condensation on an SH surface, the lack of robustness and abrasion resistance of most of the SH surfaces, the drawbacks of the fabricated self-healing SH surfaces, the short useful service life of self-cleaning SH surfaces due to surface contamination, and the ineffective anti-icing SH coatings are reviewed in the following text. Some important problems affecting the unsuccessful industrial applications of the SH surfaces are discussed critically in the Conclusions and Outlook section. Finally, some proposals are presented for future directions on the synthesis and applications of SH surfaces.

From Extremely Water-Repellent Coatings to Passive Icing Protection—Principles, Limitations and Innovative Application Aspects

The severe environmental conditions in winter seasons and/or cold climate regions cause many inconveniences in our routine daily-life, related to blocked road infrastructure, interrupted overhead telecommunication, internet and high-voltage power lines or cancelled flights due to excessive ice and snow accumulation. With the tremendous and nature-inspired development of physical, chemical and engineering sciences in the last few decades, novel strategies for passively combating the atmospheric and condensation icing have been put forward. The primary objective of this review is to reveal comprehensively the major physical mechanisms regulating the ice accretion on solid surfaces and summarize the most important scientific breakthroughs in the field of functional icephobic coatings. Following this framework, the present article introduces the most relevant concepts used to understand the incipiency of ice nuclei at solid surfaces and the pathways of water freezing, considers the criteria that a given material has to meet in order to be labelled as icephobic and clarifies the modus operandi of superhydrophobic (extremely water-repellent) coatings for passive icing protection. Finally, the limitations of existing superhydrophobic/icephobic materials, various possibilities for their unconventional practical applicability in cryobiology and some novel hybrid anti-icing systems are discussed in detail.

Improvement in Tribological Properties of Cr12MoV Cold Work Die Steel by HVOF Sprayed WC-CoCr Cermet Coatings

The main objective of this study was to develop an efficient coating to increase the wear resistance of cold work die steel at different temperatures. The microstructures of high-velocity oxygen-fuel (HVOF)-sprayed WC-CoCr coatings were evaluated using scanning electron microscopy (SEM) and transmission electron microscopy (TEM). The effect of temperature on the tribological properties of the coatings and the reference Cr12MoV cold work die steel were both investigated by SEM, environmental scanning electron microscopy (ESEM), X-ray diffraction (XRD), and a pin-on-disk high-temperature tribometer. The coating exhibited a significantly lower wear rate and superior resistance against sliding wear as compared to the die steel at each test temperature, whereas no major differences in terms of the variation tendency of the friction coefficient as a function of temperature were observed in both the coatings and the die steels. These can be attributed to the presence of nanocrystalline grains and the fcc-Co phase in the coating. Moreover, the wear mechanisms of the coatings and the die steels were compared and discussed. The coating presented herein provided a competitive approach to improve the sliding wear performance of cold work die steel.

Anti-Graffiti Behavior of Oleo/Hydrophobic Nano-Filled Coatings Applied on Natural Stone Materials

In recent years, graffiti writings are increasingly regarded as a form of art. However, their presence on historic building remains a vandalism and different strategies have been developed to clean or, preferably, protect the surfaces. In this study, an experimental nano-filled coating, based on fluorine resin containing SiO2 nano-particles, and two commercial products have been applied on compact and porous calcareous stones, representative of building materials used in the Mediterranean basin, and their anti-graffiti ability has been analyzed. All the tested experimental and commercial coatings exhibited high hydrophobicity and oleophobicity, thus meeting one of the basic requirements for anti-graffiti systems. The effects of staining by acrylic blu-colored spray paint and felt-tip marker were, then, assessed; the properties of the treated stone surfaces after cleaning by acetone were also investigated. Visual observations, contact angle measurements and color evaluations were performed to this aim. It was found that the protective coatings facilitated the spray paint removal; however high oleophobicity or paint repellence did not guarantee a complete cleaning. The stain from the felt-tip marker was confirmed to be extremely difficult to remove. The cleaning with a neat unconfined solvent promoted the movement of the applied polymers (and likely of the paint, as well) in the porous structure of the stone substrate.

Durable superamphiphobic coatings from one-step electrostatic dusting

Superamphiphobic coatings are fabricated via electrostatic dusting using modified silica particles and polymethyl methacrylate resin particles on conductive substrates (metal and conductive glass). The obtained translucent superamphiphobic coatings show excellent durability and chemical robustness even after exposure to strong acids and bases. Importantly, the coatings maintain hydrophobicity even after 100 cycles of abrasion testing and 1000 cycles of finger wiping. In addition, the fabricated coatings are superoleophobic after finger wiping, tape peeling and oil immersion. This facile strategy may provide researchers in related fields with new avenues for improving powder coatings in practical applications.

Self-Limiting Processes in the Flame-Based Fabrication of Superhydrophobic Surfaces from Silicones

Outdoor applications of superhydrophobic coatings require synthetic approaches that allow their simple, fast, scalable, and environmentally benign deployment on large, heterogeneous surfaces and their rapid regeneration in situ. We recently showed that the thermal degradation of silicones by flames fulfills these characteristics by spontaneously structuring silicone surfaces into a hierarchical, textured structure that provides wear-resistant, healable superhydrophobicity. This paper elucidates how flame processing-a simple, rapid, and out-of-equilibrium process-can be so counterintuitively reliable and robust in producing such a complex structure. A comprehensive study of the effect of the processing speed and flame temperature on the chemical and physical properties of the coatings yielded three surprising results. (i) Three thermal degradation mechanisms drive the surface texturing: depolymerization (in the O₂-rich conditions of the surface), decomposition (in the O₂-poor conditions found a few micrometers from the surface), and pyrolysis at excessive temperatures. (ii) The operational condition is delimited by the onset of the depolymerization at low temperatures and the onset of pyrolysis at high temperatures. (iii) The remarkably wide operational conditions and robustness of this approach result from self-limiting growth and oxidation of the silicone particles that are responsible for the surface texturing and in the extent of their deposition. As a result of this analysis we show that superhydrophobic surfaces can be produced or regenerated with this approach at a speed of 15 cm s^-1 (i.e., the length of an airport runway in ∼4.5 h).

Assembly Mechanism and the Morphological Analysis of the Robust Superhydrophobic Surface

Robust superhydrophobic surfaces are fabricated on different substrates by a scalable spray coating process. The developed superhydrophobic surface consists of thin layers of surface functionalized silica nanoparticle (SiO2) bound to the substrate by acrylate-polyurethane (PU) binder. The influence of the SiO2/PU ratio on the superhydrophobicity, and the robustness of the developed surface, is systematically analyzed. The optimized SiO2/PU ratio for prepared superhydrophobic surfaces is obtained between 0.9 and 1.2. The mechanism which yields superhydrophobicity to the surface is deduced for the first time with the help of scanning electron microscopy and profilometer. The effect of mechanical abrasion on the surface roughness and superhydrophobicity are analyzed by using profilometer and contact angle measurement, respectively. Finally, it is concluded that the binder plays a key role in controlling the surface roughness and superhydrophobicity through the capillary mechanism. Additionally, the reason for the reduction in performance is also discussed with respect to the morphology variation.

Durability and Wear Resistance of Laser-Textured Hardened Stainless Steel Surfaces with Hydrophobic Properties

Hydrophobic surfaces are of high interest to industry. While surface functionalization has attracted significant interest, from both industry and research, the durability of engineered surfaces remains a challenge, as wear and scratches deteriorate their functional response. In this work, a cost-effective combination of surface engineering processes on stainless steel was investigated. Low-temperature plasma surface alloying was applied to increase surface hardness from 172 to 305 HV. Then, near-infrared nanosecond laser patterning was deployed to fabricate channel-like patterns that enabled superhydrophobicity. Abrasion tests were carried out to examine the durability of such engineered surfaces during daily use. In particular, the evolution of surface topographies, chemical composition, and water contact angle with increasing abrasion cycles were studied. Hydrophobicity deteriorated progressively on both hardened and raw stainless steel samples, suggesting that the major contributing factor to hydrophobicity was the surface chemical composition. At the same time, samples with increased surface hardness exhibited a slower deterioration of their topographies when compared with nontreated surfaces. A conclusion is made about the durability of laser-textured hardened stainless steel surfaces produced by applying the proposed combined surface engineering approach.

One-Step Potentiostatic Deposition of Micro-Particles on Al Alloy as Superhydrophobic Surface for Enhanced Corrosion Resistance by Reducing Interfacial Interactions

Corrosion failure is a thorny problem that restricts the application of Al alloys. As a new technique for functional realization, hydrophobic preparation offers an efficient approach to solve corrosion problem. This work has developed a facile and low-cost method to endow Al alloy with enhanced water-repellent and anticorrosion abilities. The micro-particles have been firstly prepared by one-step deposition process. Furthermore, wetting and electrochemical behaviors of as-prepared structures have been investigated after silicone modification. Results show that the fabricated surface possesses excellent superhydrophobicity with a water contact angle (CA) of 154.7° and a sliding angle (SA) of 6.7°. Meanwhile, the resultant surface is proved with enhanced corrosion resistance by reducing interfacial interactions with seawater, owing to newly-generated solid-air-liquid interfaces. This work sheds positive insights into extending applications of Al alloys, especially in oceaneering fields.

Biomimetic self-slippery and transferable transparent lubricant-infused functional surfaces

Self-slippery liquid-infused porous surfaces (SLIPSs) have been presented owing to their enormous number of potential applications and have widely attracted the attention of researchers in recent years. In comparison with superhydrophobic surfaces, SLIPSs not only exhibit interfacial performance that corresponds to superhydrophobicity but also do not require the construction of a complicated and delicate morphology. Here, a facile strategy has been proposed for constructing silica SLIPSs. Three common lubricants (perfluoropolyethers, liquid paraffin and ethyl oleate) were employed in this study. Using a facile brush process, the surface can be coated on a substrate, and, after infusion of the lubricant, the transformation from superhydrophobicity to self-slippage properties can be achieved. In addition, changing the kind of lubricant and adjusting the amount of nanoscale hybrid silica particles in the coating solution can modulate the surface transparency and interfacial characteristics, which makes the surface meet the various requirements of different service conditions. This transferable performance endows the surface with the possibility of meeting the various requirements of different conditions and demonstrates the enormous value of the application of the coatings in many fields.

Superhydrophobic Fabrics with Mechanical Durability Prepared by a Two-Step Plasma Processing Method

Most studies on superhydrophobic fabrics focus on their realization using additive manufacturing (bottom-up) techniques. Here we present the direct modification of three different fabrics using a plasma-based method to obtain anti-adhesive and self-cleaning properties. A two-step plasma processing method is used: (a) for the creation of micro-nanoscale features on the fabric surface (plasma texturing step) and (b) the minimization of the fabric surface energy (by a short plasma deposition step of a very thin, low surface energy layer). The entire process takes only 14 min and all fabrics after processing exhibit high water static contact angles (WSCA > 150°), low contact angle hysteresis (CAH < 7°) and advantageous mechanical durability against hand-rumpling. The method is simple and generic, and it can be therefore expanded to other polymeric fabrics (i.e., acrylic) in addition to polyester, without any limitation rising from the weaving characteristics of the fabric or the starting nature of the material (i.e., hydrophobic or hydrophilic).

The anti-soiling performance of highly reflective superhydrophobic nanoparticle-textured mirrors

The anti-soiling (AS) performance of solar mirrors coated with a highly transparent, superhydrophobic nanoparticle-textured coating has been characterized. The AS coatings were created on the mirror surface by depositing nano-textured silica nanoparticle layers of ∼250 nm thickness using a draw-down coating process, followed by fluorination of the nanoparticles in a molecular vapor deposition process. Highly uniform surface features of the AS-coated mirrors (20 × 30 cm2, no measurable loss in specular reflectance, and water contact angle >165°) provided an outstanding AS performance. A 4× reduction in the rate of dust accumulation as determined by gravimetric measurement of the accumulated dust on coated versus uncoated mirrors was observed. Additional evidence of a significant reduction in soiling rate was determined during measurements of specular reflectance in an outdoor environment test. The adhesion force between a model sand particle and nano-textured coatings in the hydrophobic to superhydrophobic range was also studied. A dramatic decrease in adhesive force acting on the particle was observed with increasing surface hydrophobicity. The results align well with the observed dust accumulation on the AS-coated mirrors. The AS-coated mirror maintains a high reflectivity by shedding dust and resisting dust accumulation, providing a potential benefit when applied to mirrors in the solar field of a concentrated solar power generation plant.

Multifunctional Hierarchical Surface Structures by Femtosecond Laser Processing

Hierarchical surface structures were fabricated on fused silica by using a fs-laser with a pulse duration τ = 300 fs and a wavelength λ = 512 nm. The resulting surface structures were characterized by scanning electron microscopy, atomic force microscopy and white light interference microscopy. The optical properties were analyzed by transmittance measurements using an integrating sphere and the wettability was evaluated by measuring the water contact angle θ. The silanization of structured fused silica surfaces with trichloro(1H,1H,2H,2H-perfluorooctyl)silane allows to switch the wettability from superhydrophilic (θ = 0°) to superhydrophobic behavior with θ exceeding 150°. It was shown that the structured silica surfaces are a suitable master for negative replica casting and that the hierarchical structures can be transferred to polystyrene. The transmittance of structured fused silica surfaces decreases only slightly when compared to unstructured surfaces, which results in high transparency of the structured samples. Our findings facilitate the fabrication of transparent glass samples with tailored wettability. This might be of particular interest for applications in the fields of optics, microfluidics, and biomaterials.

Facile preparation of high density polyethylene superhydrophobic/superoleophilic coatings on glass, copper and polyurethane sponge for self-cleaning, corrosion resistance and efficient oil/water separation

Inspired by the lotus effect and water-repellent properties of water striders' legs, superhydrophobic surfaces have been intensively investigated from both fundamental and applied perspectives for daily and industrial applications. Various techniques are available for the fabrication of artificial superoleophilic/superhydrophobic (SS). However, most of these techniques are tedious and often require hazardous or expensive equipment, which hampers their implementation for practical applications. In the present work, we used a versatile and straightforward technique based on polymer drop-casting for the preparation SS materials that can be implemented on any substrate. High density polyethylene (HDPE) SS coatings were prepared on different substrates (glass, copper mesh and polyurethane (PU) sponge) by drop casting the parent polymer xylene-ethanol solution at room temperature. All the substrates exhibited a superhydrophobic behavior with a water contact angle (WCA) greater than 150°. Furthermore, the corrosion resistance, stability, self-cleaning property, and water/oil separation of the developed materials were also assessed. While copper mesh and PU sponge exhibited good ability for oil and organic solvents separation from water, the HDPE-functionalized PU sponge displayed good adsorption capacity, 32-90 times the weight of adsorbed substance vs. the weight of adsorbent.

Surface-Segregation-Induced Nanopapillae on FDTS-Blended PDMS Film and Implications in Wettability, Adhesion, and Friction Behaviors

Polymer composites have been extensively used to tune the surface property (e.g., wettability, friction, and adhesion) for its advantages of cost-effectiveness, high efficiency, and ease of fabrication. In this work, different amount of trichloro(1H,1H,2H,2H-perfluorooctyl)silane (FDTS) was added into poly(dimethylsiloxane) elastomer to prepare polymer composite films and were selected as a model to illustrate the effects of surface segregation on surface topology, wettability, friction, and adhesion. The results show that the added FDTS forms aggregations and increasing the content of FDTS leads to the difficulty of air bubble elimination, increase in viscosity, and drop in transparency. Driven by the differences of chemical potential, FDTS aggregations migrate to the air-polymer interface, resulting in surface enrichment and formation of nanopapillae (1-200 nm). This phenomenon becomes more significant with the increment in FDTS. The change in surface composition and structure generates profound effects on wettability, friction, and adhesion. The addition of FDTS makes the surface relatively oleophobic and further increasing the content of FDTS does not helpful in improving the oleophobicity due to the notable aggregation. Friction forces first grow with the increasing content of FDTS and then decline after the maximum point at 1.0 wt % of FDTS, which is attributed to the generated regular larger nanopappillae at high concentration. However, these larger nanopapillae lead to the increase in adhesion because more interactions are formed. The findings demonstrate the behaviors of FDTS in polymer composites and provide important guidance for controlling the formation of nanostructures via aggregation and phase segregation and exploring their implications on surface properties.

Sustainable and long-time 'rejuvenation' of biomimetic water-repellent silica coating on polyester fabrics induced by rough mechanical abrasion

The economical use of water-repellent coatings on polymeric materials in commercial and industrial applications is limited by their mechanical wear robustness and long-term durability. In this study, we demonstrate that polyethylene terephthalate (PET) fabric modified with inorganic, methyltrimethoxysilane (MTMS)-based coatings shows excellent resistance against various types of wear damage, thereby mimicking superhydrophobic biological materials. These features were facilitated by the rational design of coating processing that also enabled tunable hierarchical surface structure. A series of custom and standard testing protocols revealed that coating-to-substrate adhesion was remarkably high, as was the resistance to various mechanical abradents. The most intriguing characteristic observed during aging and abrasion cycles was the enhancement in non-wettability or 'rejuvenation' reflected by water droplet roll-off behavior, a characteristic of self-cleaning materials. Water-repellent properties of coated polyester were also enhanced by prolonged thermal annealing and were maintained after custom laundry. The developed technology offers opportunities to design low cost, durable and functional textiles for both indoor and outdoor applications.

Durable superhydrophobic and superamphiphobic polymeric surfaces and their applications: A review

Wetting control is essential for many applications, such as self-cleaning, anti-icing, anti-fogging, antibacterial action as well as anti-reflection and friction control. While significant effort has been devoted to fabricate superhydrophobic/superamphiphobic surfaces (repellent to water and other low surface tension liquids), very few polymeric superhydrophobic/superamphiphobic surfaces can be considered as durable against various externally imposed stresses (e.g. application of heating, pressure, mechanical forces, chemical, etc.). Therefore, durability tests are extremely important for applications especially when such surfaces are made of "soft" materials. Here, we review the most recent and promising efforts reported towards the realization of durable, superhydrophobic/superamphiphobic, polymeric surfaces emphasizing the durability tests performed, and some important applications. We compare and put in context the scattered durability tests reported in the literature, and present conclusions, perspectives and challenges in the field.

Combination of Functional Nanoengineering and Nanosecond Laser Texturing for Design of Superhydrophobic Aluminum Alloy with Exceptional Mechanical and Chemical Properties

Industrial application of metallic materials is hindered by several shortcomings, such as proneness to corrosion, erosion under abrasive loads, damage due to poor cold resistance, or weak resistance to thermal shock stresses, etc. In this study, using the aluminum-magnesium alloy as an example of widely spread metallic materials, we show that a combination of functional nanoengineering and nanosecond laser texturing with the appropriate treatment regimes can be successfully used to transform a metal into a superhydrophobic material with exceptional mechanical and chemical properties. It is demonstrated that laser chemical processing of the surface may be simultaneously used to impart multimodal roughness and to modify the composition and physicochemical properties of a thick surface layer of the substrate itself. Such integration of topographical and physicochemical modification leads to specific surface nanostructures such as nanocavities filled with hydrophobic agent and hard oxynitride nanoinclusions. The combination of superhydrophobic state, nano- and micro features of the hierarchical surface, and the appropriate composition of the surface textured layer allowed us to provide the surface with the outstanding level of resistance of superhydrophobic coatings to external chemical and mechanical impacts. In particular, experimental data presented in this study indicate high resistance of the fabricated coatings to pitting corrosion, superheated water vapor, sand abrasive wear, and rapid temperature cycling from liquid nitrogen to room temperatures, without notable degradation of superhydrophobic performance.

Study on the anti-abrasion resistance of superhydrophobic coatings based on fluorine-containing acrylates with different Tg and SiO2

Mechanism of superhydrophobic coating against abrasion based on the fluorine-containing acrylates (FACs) with different T_g and SiO₂ composite coatings.

Superhydrophobic surfaces with fluorinated cellulose nanofiber assemblies for oil–water separation

Fluorinated cellulose nanofiber assemblies exhibit high oil–water separation efficiency and recyclability (at least 50 times) for practical applications.

Preparation of sponge-like porous SiO2antireflective coatings with excellent environment-resistance by an acid-catalysed sol–gel method

Silica coatings with high-transmittance and excellent environment-resistance property were prepared by adding hexamethyldisilazane (HMDS) into acid-catalyzed through sol–gel method.