Synergistic superhydrophobicity and conductivity in Zn-Co LDH/MWCNTs fabrics for low-voltage electrocatalytic degradation and oil-water separation in aviation engines

A superhydrophobic conductive fabric is fabricated via scalable spray-coating of Zn-Co LDH/MWCNTs/POTS. • The fabric achieves > 96% oil-water separation efficiency with excellent cyclic stability. • Integrated electrocatalytic function degrades organic pollutants within 2 h under low voltage. • Robust durability under abrasion, chemical, thermal, and vibration stresses is demonstrated. • COMSOL simulations reveal the wettability–pore synergy governing enhanced separation. The ingress of moisture into aircraft engine lubrication systems poses a serious threat to flight safety and component service life; consequently, there is an urgent need to develop novel multifunctional materials capable of oil-water separation and environmental remediation. In this study, a three-dimensional superhydrophobic conductive fabric with a structure resembling peacock feathers was fabricated for oil-water separation in the aerospace sector. The material was prepared by spraying a composite of zinc-cobalt layered double hydroxide (LDH), modified with perfluorooctyl triethoxysilane (POTS) and multi-walled carbon nanotubes (MWCNTs), onto a conductive fabric substrate. It exhibits superhydrophobicity (water contact angle as high as 161.2°), electrocatalytic degradation capability and oil-water separation capability. The conductive network of multi-walled carbon nanotubes enables electrocatalytic degradation at a low voltage of 20 V, whilst the superhydrophobic surface selectively allows rapid oil penetration, achieving oil-water separation efficiencies of 96–99.4% under thermal radiation conditions. The material maintains stable superhydrophobicity even after repeated cycles and exposure to mechanical abrasion, corrosive media and high-temperature ageing (220°C). COMSOL simulations elucidated the synergistic mechanism between selective wetting and thermal viscosity modulation. This study provides an integrated solution for next-generation aviation fuel systems that combines physical separation with electrocatalytic purification. Furthermore, the coating preparation process is simple and the raw materials readily available, offering significant potential for large-scale mass production. Download: Download high-res image (178KB) Download: Download full-size image A superhydrophobic conductive fabric (HCF) modified with Zn-Co LDH/MWCNTs composite was fabricated. Through micro-nano structure regulation and surface energy modification, it synergistically achieves efficient oil-water separation, low-voltage electrocatalytic degradation, and self-cleaning properties. Exhibiting excellent mechanical stability and chemical durability under harsh operating conditions of aero-engines, this material provides a multifunctional integrated solution for water pollution control and contaminant purification in aviation fuel systems.