A novel high-performance coating with hybrid nanofiller reinforcement for superior self-cleaning, anti-icing, and corrosion resistance properties

Abstract

A novel self-cleaning superamphiphobic nanocomposite coating with excellent corrosion protection, anti-icing, and mechanical properties has been developed through the integration of hybrid graphene nanoplate (GNP) and silica nanoparticle (NS) reinforcement, coupled with surface modification using fluorinated particles and polydimethylsiloxane (PDMS). The GNP/NS hybrid nanofiller imparts superior corrosion barrier performance and mechanical strength to the coating. The surface modification led to impressive contact angles of 168° for water and 150° for hexadecane. While sliding angle consistently displayed less than 10° for both fluids, signifying the coating's exceptional superamphiphobic characteristics. The coating demonstrates exceptional anti-icing performance, with significantly delayed ice formation and reduced ice adhesion. Moreover, the coating exhibits remarkable stability and durability, even after long-term exposure to corrosive and harsh weathering environments. Electrochemical impedance spectroscopy (EIS) measurements confirmed the coating's superior corrosion resistance; the impedance plot of developed coating remained unchanged and exceeded 1010 Ω/cm2 across various exposure durations, whereas the neat epoxy started with a lower impedance value that progressively diminished over the exposure period. Tensile tests revealed a 75% increase in tensile strength, 63% improvement in failure strain, and an 11% increase in Young's modulus compared to the neat epoxy. Additionally, to comprehensively elucidate the mechanisms underpinning the developed nanocomposite coating, this study utilized a range of advanced analytical methods, including SEM, EDX, XRD, FTIR, and hardness tests. The developed nanocomposite coating shows promising potential as a reliable, long-lasting protective solution for metal structures in civil, mechanical, and aerospace engineering applications.