Engineered ceramic composite coatings via multiscale binder synergy: Achieving dynamic icephobicity and mechanical robustness

Addressing Wenzel-state wetting transition and structural instability in superhydrophobic coatings under cryogenic humidity and mechanical stress, this work develops a multiscale binder synergized with ceramic cellular fillers to in situ fabricate a composite coating integrating efficient anti-icing/deicing with robust durability. Precise modulation of acrylic resin (AR) phase separation dynamics induces topological reconstruction of the dynamic bonding network in aluminum dihydrogen phosphate (SADP), yielding in situ-grown SADP nanorods (aspect ratio is 5.1) within micropores that enhance coating puncture resistance and hydrophobic stability, suppress frost-bridging propagation, and provide bubble coalescence matrices, achieving gas-liquid/solid-liquid asymmetric lifted freezing at −20 °C and 95 % RH, spontaneous ice-shedding at 75 % RH, and passive deicing via Wenzel-to-Cassie transition during melt. The rebar-concrete-mimetic skeleton formed by ADP-AR matrix intertwined with ceramic cellular fillers endowing superior durability: maintaining 155° contact angle (initial 159.8°) post 360 abrasion cycles with resistance to weathering, thermal cycling (−20 °C–150 °C), peeling, UV radiation, and chemical exposure, delivering a long-term anti-icing solution for wind turbine blades in extreme environments.