Corrosion Resistance of Superhydrophobic and Nanosilica Coatings



A staff of researchers just lately printed a paper within the journal Scientific Studies that evaluated the corrosion efficiency of metal substrates coated utilizing superhydrophobic nanosilica and polytetrafluoroethylene (PTFE) coatings.

Corrosion Resistance of Superhydrophobic and Nanosilica Coatings​​​​​​​

​​​​​​​Research: Analysis of corrosion efficiency of superhydrophobic PTFE and nanosilica coatings. Picture Credit score: ON-Pictures Germany/

Significance of Corrosion Safety in Metals

Metallic is among the most extensively used supplies in several industrial sectors, corresponding to medical, building, transportation, and protection. Nonetheless, steel gear and constructions are susceptible to corrosion when they’re uncovered to moisture and antagonistic environmental situations. Corrosion causes gradual lack of efficiency in steel gear and constructions and finally results in their destruction.

Limitations of Current Corrosion Safety Mechanisms

A number of strategies based mostly on anodic and cathodic safety, coatings, and corrosion inhibitors are utilized to stop corrosion in metals. Amongst them, the coating methodology is usually used to guard steel constructions from chemical compounds, oxidation, and moisture. On this methodology, completely different substances are used to ascertain a barrier between the steel floor and the corrosive surroundings.

Coating strategies, corresponding to phosphating and chromating, are sometimes used to guard the steel floor. Nonetheless, these strategies are carcinogenic and poisonous to people, and environmentally dangerous. A number of international locations have prohibited using these substances to stop the corrosion of metals.

Improvement of Different Coatings

A number of research have been carried out to develop coatings utilizing different supplies. Supplies corresponding to uncommon earth compound movies and sol-gel-derived movies have demonstrated their anti-corrosion capacity. Coatings with extraordinarily low electrical conductance, corresponding to non-conducting silica/silicon dioxide (SiO2), titanium dioxide (TiO2), and aluminum oxide (Al2O3) coatings, are additionally efficient in corrosion safety.

Superhydrophobic Coatings

Superhydrophobic coatings with larger than 150 levels contact angles and decrease than 10 levels roll-off angles have gained consideration for anti-corrosion purposes in metals. The anti-corrosion habits of steel surfaces improves when coated with superhydrophobic coatings as a result of low contact space and quick contact time.

These coatings defend metals from corrosion attributable to the penetration of electrolytes within the steel substrate. Superhydrophobic coatings, corresponding to PTFE and nanosilica coatings, could be fabricated in steel and alloy surfaces, together with magnesium, zinc, aluminum, and copper.

The present strategies used to manufacture PTFE coatings on steel surfaces, together with chemical vapor deposition (CVD) and electrospray, usually don’t create a superhydrophobic floor on metals or have a number of operational limitations.

As an example, the electrospray methodology results in macro-molecule degradation owing to the variation in working temperatures, whereas controlling the coating uniformity is troublesome utilizing the CVD methodology. The electrodeposition method is taken into account a extra appropriate methodology for steel floor coating as it’s cheap and could be utilized on advanced and enormous steel surfaces.

Corrosion Efficiency of Metal Coated with Superhydrophobic PTFE and Nanosilica Coatings

On this research, researchers used the electrodeposition and spraying course of to analyze the corrosion efficiency of metal coated with superhydrophobic nanosilica hybrid movie and PTFE coatings.

The PTFE superhydrophobic coating was fabricated by spraying on the metal floor as the tactic is easy with no operational limitations and can be utilized on all steel surfaces. The hierarchical construction within the superhydrophobic coatings was achieved utilizing Al2O3 and glass bead microparticles and SiO2 nanoparticles as supplies with extraordinarily low electrical conductance.

Researchers additionally ready superhydrophobic PTFE coatings with completely different specs to evaluate the anti-corrosion habits of the fabricated PTFE coating. Particularly, they evaluated the impact of utilizing two completely different microparticle varieties, together with glass beads and Al2O3, within the primer layer and an overcoat layer with and with out SiO2 nanoparticles on the anti-corrosion properties of the PTFE coatings.

Nanosilica superhydrophobic coatings have been fabricated by means of the electrodeposition of inorganic/natural hybrid sol-gel movies derived from tetraethoxysilane (TEOS) and dodecyltrimethoxysilane (DTMS) combined sol-gel precursors to carry out a comparative research between the anti-corrosion habits of PTFE coatings and nanosilica coatings.

Moreover, the corrosion habits of uncoated metal substrates was additionally evaluated and in contrast with the coated samples. Electrochemical impedance spectroscopy and TOEFL polarization assessments have been carried out on the coated metal samples to analyze their corrosion efficiency in 3.5 weight share sodium chloride answer at 25 levels Celsius temperature.

Significance of the Research

Nanosilica coating, PTFE coating with glass beads microparticles within the primer layer and an overcoat layer with/with out SiO2 nanoparticles, and PTFE coatings with Al2O3 microparticles within the primer layer and SiO2 nanoparticles within the overcoat layer have been fabricated efficiently on the metal substrates.

All coated metal samples demonstrated a better corrosion resistance than the uncoated samples. Among the many coated samples, PTFE coating with glass beads microparticles displayed the very best corrosion resistance.

PTFE coating with glass bead microparticles confirmed a better corrosion resistance in comparison with the PTFE coating with Al2O3 microparticles and silica movie coating as a result of decrease conductivity of the Al2O3 powder and thickness of the silica movie.

PTFE coating with SiO2 nanoparticles within the overcoat layer and glass bead microparticles within the primer layer displayed larger corrosion resistance than the PTFE coating with glass bead microparticles and with out SiO2 nanoparticles. The SiO2 nanoparticles improved the corrosion resistance by sealing the pores and defects within the PTFE coating.

Amongst all coatings, PTFE coating with glass beads, microparticles and SiO2 nanoparticles displayed the simplest anti-corrosion habits because it diminished the corrosion charge by 80 occasions in comparison with the corrosion charge of the uncoated pattern. 


Haji-Savameri, M. et al. (2022). Analysis of corrosion efficiency of superhydrophobic PTFE and nanosilica coatings. Scientific Studies.

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