Nano sponge like metal-based coating with self-regenerative superhydrophobicity using simple flame spraying

Abstract

In present investigation, a low-cost and facile fabrication route for developing nano-sponge like aluminum coating on carbon steel through flame spraying is demonstrated. The silanization of coating resulted in highly de-wetting state with contact angle >152°, low contact angle hysteresis and sliding angle (<5°). The coating also showed low adhesion force of 6 µN with water. The superhydrophobic coating showed 56 times lower corrosion rate than carbon steel due to high polarization resistance. The coating showed self-regenerative nature during abrasion resulting in persistent superhydrophobicity. High durability was also observed during exposure to rain, weathering, and long-time immersion.