Rammed earth-inspired superhydrophobic monolith with superior wear resistance and self-regenerative recyclability

Superhydrophobic materials have garnered significant interest due to their exceptional performance across various applications. However, conventional superhydrophobic coatings are susceptible to degradation in extreme environments, resulting in functional failure. Drawing inspiration from ancient Chinese rammed earth technology, this study introduces a novel superhydrophobic monolith with a uniform structure and self-regenerative recyclability, fabricated through a stamping process. The developed monolith exhibits a remarkably high contact angle (157.2°) and a low roll-off angle (2.7°). It consists of room-temperature vulcanized (RTV) silicone rubber and superhydrophobic silica nanoparticles synthesized via high-pressure stamping.Through the integrated“polymer + nano-component”stamping approach, the fabricated superhydrophobic monolith achieves a compact and continuous internal structure, coupled with high compressive strength. Following 20,000 abrasion cycles under a 250 g load using rigid ceramic grinding wheels, the material exhibits a mass loss of only 26.501 r/g and a thickness loss of 14.932 r/mm, significantly surpassing the durability of other superhydrophobic materials. Notably, the worn surface retains its superhydrophobic properties.Furthermore, the monolith displays outstanding resistance to acid/alkali corrosion, salt spray exposure, and UV-induced degradation. The structural integrity imparted by the stamping process ensures the retention of its initial superhydrophobicity during recycling, underscoring its suitability for post-use recovery. This advancement expands its potential applications in industrial settings.