Development of Durable and Multifunctional Superhydrophobic Ceramic/Fluoropolymer Coatings by One-Step Thermal Spraying Methodology

Superhydrophobic coatings have attracted increasing attention due to their exceptional performance. Although these materials are becoming more widely employed, there are still a number of critical challenges, such as complex or costly fabrications, poor long-term stability, weak interfacial bonding between ceramics and fluoropolymers, and others, that may limit their application in large areas. This study presents the creation of a durable and versatile superhydrophobic Al 2 O 3 /Polytetrafluoroethylene (PFA) composite coating via a one-step thermal spraying technique. Results show that the formation of interdiffusion layer between Al 2 O 3 and PFA splats could be responsible for robust interfacial bonding. The composite coating retains its superhydrophobic properties after 100 cycles of wear with 1000-grit sandpaper subjected to a load of 100 g (equivalent to a friction distance of 2000 cm). With the challenges of bending damage and high-strength wear, the superhydrophobic Al 2 O 3 /PFA composite coating exhibits remarkable self-cleaning efficacy against various liquids. The robust hybrid coating features straightforward preparation, outstanding characteristics, and durability, potentially generating significant interest in the engineering application sector.