Synthesis of robust superhydrophobic EP/F-CNTs/SiO2 composite coating with excellent anti-corrosion and wear-resistant property

At present, superhydrophobic coatings have a wide range of applications in self-cleaning, drag reduction, and corrosion protection. However, their poor mechanical stability has a significant impact on the service life and effectiveness of the coatings. In addressing this challenge, this study introduced epoxy resin (EP) with high strength and strong adhesion as the resin matrix. The composite coating, synthesized through a straightforward spraying technique, incorporates modified carbon nanotubes (F-CNTs) and hydrophobic fumed nanosilica (SiO₂) as fillers. The robust EP/F-CNTs/SiO₂ superhydrophobic coating exhibited excellent anti-rubbing ability and superadhesion strength, which was attributed to the EP intermediate layer significantly enhancing the adhesion strength between the coating and the stainless steel substrate with a remarkable adhesion grade of one. Tafel and EIS test results revealed a corrosion inhibition efficiency of up to 99.75% for the coating. The exceptional corrosion resistance of the coating is attributed to the outstanding electron transfer capability of F-CNTs. In addition, the coating could resist corrosion from strong acids and bases. It is believed that the facile and low-cost method offers an effective strategy and promising industrial applications for fabricating robust and super anti-corrosion superhydrophobic surfaces on various metallic materials.