Superhydrophobic Surface Modification of 3D-Printed ZrO2 Ceramics: Structural Design and Wear Resistance Investigation

In this study, zirconia (ZrO 2 ) ceramics exhibiting exceptional mechanical properties were fabricated utilizing vat photopolymerization (VPP) 3D printing technology. Subsequent surface modification was conducted to convert the material from a hydrophilic to a superhydrophobic state. An inverted triangle pyramid structural model was devised to safeguard the superhydrophobic surface by means of its architectural design, culminating in the development of wear-resistant superhydrophobic ZrO 2 ceramics. Comprehensive investigations were conducted into process optimization, microstructural characteristics, mechanical attributes, hydrophobicity, and tribological properties. The findings revealed that utilizing BYK-111 as a dispersant at a concentration of 2.5 wt.% yields optimal rheological behavior of the ZrO 2 ceramics slurry, conducive to 3D printing applications. At a sintering temperature of 1550 °C, the ZrO 2 ceramics attained a density of 99.3%, while its Vickers hardness and flexural strength peaked at 1465.02 HV and 641.87 MPa, respectively. The findings revealed that the surface contact angle of the modified ceramics specimen attained 157 , signifying outstanding superhydrophobic characteristics. To preserve its superhydrophobic microstructure from abrasion-induced damage, a three-dimensional architecture featuring minute inverted pyramids was engineered to shield the superhydrophobic surface. To investigate the impact of varying inverted pyramid geometries and dimensions on wear resistance, a range of alternative structural configurations were devised for wear testing. The wear resistance of ceramics with these distinct structural forms was assessed by comparing their contact angles. This research offers an innovative, cost-effective, and efficient approach for fabricating superhydrophobic materials within the ceramics sector, thereby improving their wear resistance.