Corrosion Resistance Properties Research Articles

The impact of LSM pretreatment on the growth behavior, electrical insulation and corrosion resistance properties of PEO coating on 6061 aluminum alloy

This work reported the influence of laser surface melting (LSM) pretreatment on the growth behavior, electrical insulation and corrosion resistance of plasma electrolytic oxidation (PEO) film on 6061 aluminum alloy. It is found that the LSM pretreatment refines the surface structure of original Al metal, generating defects that store excessive energy, thereby enhancing reaction kinetics and phase transition during the PEO process. By LSM pretreatment, uniform electrical discharge and film growth can be obtained, resulting in fewer defects and lower porosity in PEO layers. Additionally, a large amount of columnar crystals comprising of SiO2 phase are observed, which transformed from the SiO32− deposited on the surface, and the LSM pretreatment significantly improves the electrical insulation, corrosion resistance, and substrate adhesion of following PEO layer. Under the same PEO treatment duration, the breakdown voltage of coating increased by 100 V, and icorr decreased from 3.26 × 10−4 to 9.13 × 10−6 A cm−2. It is expected that the combination of LSM and PEO processes can not only enhance the surface properties of Al metal, but also expand the practical application of aluminum alloy in high-power electronic devices and related fields.

Corrosion Assessment of Arc Thermal Sprayed Al and its Alloy Coatings in Aggressive Environments: An Overview

Arc thermal sprayed coatings have a wide range of applications, including corrosion resistance, wear resistance, thermal barriers, and electromagnetic pulse protection. However, these coatings often suffer from significant defects and pore formation, which can reduce their overall effectiveness. This overview focuses on the corrosion resistance properties of Al and its alloys. Al coatings demonstrate good corrosion resistance in marine environments due to the formation of sparingly soluble corrosion products on the surface. When Zn is alloyed with Al, the initial corrosion resistance decreases due to an increased number of pores. However, over extended exposure, these coatings exhibit excellent corrosion resistance as corrosion products fill the pores, providing barrier protection. Additionally, incorporating 5 wt.% Mg in Al coatings enhances bond adhesion and improves corrosion resistance in aggressive environments. To further reduce porosity and enhance corrosion resistance, the use of phosphate-based eco-friendly pore sealing agents is discussed. Optimizing the amount of phosphate during treatment is crucial, as it significantly reduces porosity and enhances corrosion resistance. Both insufficient and excessive amounts of phosphate can deteriorate the coating, while the optimal amount improves corrosion resistance over prolonged exposure to aggressive conditions.

The development of a porous nickel/polysiloxane superhydrophobic coating with long-time corrosion resistance properties

Superhydrophobic (SH) coatings have great potential to protect metals by reducing the contact area between metals and corrosive media. However, the poor mechanical stability of SH coatings restricts their potential applications. In this study, a nickel underlayer with a multi-hierarchical structure was deposited on the substrate using two-step electroplating in a nickel-plating bath. Finally, the SH coating was obtained by electrodeposition in an octamethyltrisiloxane solution. The morphology, composition, hydrophobicity, and corrosion resistance of SH coating were characterized using scanning electron microscopy (SEM), X-ray photoelectron spectroscopy (XPS), Fourier transform infrared spectroscopy (FT-IR), contact angle measurement, and electrochemical workstation. The prepared coating, with a water contact angle (WCA) of 157.5 ± 0.5° and a sliding angle (SA) of 4.3 ± 0.4°, exhibited excellent hydrophobicity due to the multi-hierarchical rough structure and low surface energy of the coating. The porous structure of the coating allowed its hydrophobic properties to be maintained even after 240 cm of sandpaper abrasion testing. After 20 days of immersion in 3.5 wt% NaCl solution, the coating still exhibited excellent corrosion resistance (icorr ∼ 1.01 × 10−8 A⋅cm−2) and hydrophobic properties (∼ 148.5 ± 0.5°), providing long-lasting protection to the substrate and prolonging its lifespan. This study introduces a strategy for preparing long-term corrosion-resistant SH coating on metallic surfaces.

Noncontact Fiber-Optic Cantilever-Enhanced Photoacoustic Spectroscopy.

Conventional cantilever-enhanced photoacoustic spectroscopy (CEPAS) usually requires the cantilever to be in contact with the gas, which limits its application in dusty and corrosive gas sensing. To overcome this challenge, this paper proposes noncontact fiber-optic cantilever-enhanced photoacoustic spectroscopy (NCFO-CEPAS) for high-sensitivity trace gas analysis. A polyethylene film with corrosion-resistant properties is affixed to the end of the cantilever acoustic sensor, and the effect of the distance between the polyethylene film and the cantilever acoustic sensor on the sensitivity of the system is analyzed by finite element analysis. Compared to the conventional CEPAS, NCFO-CEPAS has a lower background noise deviation. Besides, the potential damage to the silicon cantilever beam by corrosive gases can be avoided as the gas to be measured is not in contact with the silicon cantilever beam, and the gap of the cantilever beam will not be blocked in a high dust environment. Experimental results show that the detection limit of C2H2 gas is 0.5 ppm, and the normalized noise equivalent absorption coefficient reaches 5.93 × 10-9 cm-1 W Hz-1/2. The NCFO-CEPAS technique has the advantages of noncontact remote gas monitoring, not being corroded by gases, and high resistance to electromagnetic interference.

Experimental investigation of comprehensive performance by tailoring the proportion of late transition metals in quinary Fe-Co-Ni-Si-B amorphous alloys

We fabricated the Fe-Co-Ni-Si-B multi-principal element alloys by vacuum melt-spinning method. The effects of late transition metals proportion in quinary alloy ribbons on the formation, phase structure, thermal stability, microhardness, corrosion resistance and soft magnetic properties were investigated. The melt-spun structure consists of an amorphous single phase for all the specimens. The surfaces of glassy ribbons are rather flat and flawless and the average surface roughness is 0.351 nm or below. The initial crystallization temperature (Tx) and supercooled liquid region (ΔTx) of alloy system decrease by degrees with increasing Co and Ni content, showing the maximum values of 753.0 K and 60.0 K for Fe60Co10Ni10Si6B14 alloy. But the glass transition temperature (Tg) seems to barely change and maintain approximately 692.0 K. All the as-received alloy ribbons exhibit good bending ductility and acceptable Vickers microhardness ranging from 671 to 785 HV0.5. The amorphous alloy ribbons present a gradually wide passive potential range (ΔE) with the decrease of Fe content, but the corrosion current density (Icorr) becomes larger. The smallest Icorr value is 1.785 μA·cm-2 for Fe60Co10Ni10Si6B14 alloy and the widest ΔE value is about 0.272 V for Fe26Co27Ni27Si6B14 alloy. The saturation magnetization of these glassy alloys reduces from 165.0 to 112.0 emu/g as the Fe content decreases. Meanwhile, the coercivity also changes from 14.25 to 6.70 A/m. This paper offers a brand-new perspective to understand the role of late transition metals on the various physicochemical properties of quinary Fe-Co-Ni-Si-B amorphous alloys.

Design and characterization of novel Ti-8Mo-xFe-yCu alloys as implant materials: Evaluation of biocompatibility, mechanical properties, and antibacterial potential

Titanium and its alloys are highly desirable materials for biomedical metallic implants due to their superior specific strength, excellent corrosion resistance, and exceptional biocompatibility. Among these alloys, Ti6Al4V is widely used in practical biomedical applications because it offers an excellent combination of strength, fracture toughness, and corrosion resistance. However, recent research has revealed limitations in its biocompatibility attributed to the presence of toxic elements such as Al and V. In addition, it has been reported that Ti6Al4V is costly due to the addition of Vanadium and has the potential for post-implant inflammation. As a result, researchers have been investigating new biomedical beta-Ti alloys using biocompatible, affordable, and easily accessible beta-stabilizers like Mo, Fe, and Cu, to achieve similar performance as Ti6Al4V alloys. The present study aims to develop a novel biomedical alloy through the arc melting method, to obtain an implant material possessing low elastic moduli, biocompatibility, and antibacterial properties to mitigate the risk of post-implant inflammation. Microstructural analysis was conducted using microscopy and x-ray diffraction, while the mechanical properties were evaluated through micro vickers hardness testing machine and elastic moduli measurement utilizing the impulse excitation technique. Cytotoxicity assessment was performed using the (Cell Counting Kit-8) CCK-8 method, followed by an examination of the alloy's antibacterial properties using the point counting method. β-Ti single phase was obtained in this study with the addition of ≥1% Fe and ≥1% Cu. The Ti-8Mo-2Fe-2Cu alloy was found to have the lowest elastic moduli of 95 GPa. Electrochemical measurements show that the Ti-8Mo- xFe- yCu alloys have a lower corrosion current density of around 0.319–2.317 µA/cm2 compared to Ti6Al4V of 16.543 µA/cm2. The Ti-8Mo-1Fe-3Cu, Ti-8Mo-3Fe-1Cu, and Ti-8Mo-3Fe-3Cu alloys have comparable biocompatibility with Ti6Al4V with the viability of mesenchymal stem cells (MSCs) above 75% and have a positive antibacterial response. Ti-8Mo-3Fe-3Cu alloy demonstrates the most favorable blend of microstructure, mechanical attributes, corrosion resistance, cell viability, and antibacterial properties as an alternate biomaterial for implant applications.

Unveiling the tribological and corrosion characteristics of Ti20-Al16-V16-Fe16-Ni16-Cr16 high-entropy alloy developed via spark plasma sintering

This research explores the corrosion resistance and anti-wear property of near-equimolar Ti20-Al16-V16-Fe16-Ni16-Cr16 High Entropy Alloys (HEAs), fabricated at varying temperatures through spark plasma sintering (SPS) procedure. The alloy powders were processed and sintered at temperatures ranging from 700°C to 1100°C, and the resulting HEAs underwent comprehensive characterization. The tribological behavior of these sintered HEAs and their corrosion response in sulfuric and chloride environments were systematically investigated. Microstructural analyses were conducted before and after exposure to corrosive media using a scanning electron microscope. Notably, the assessments in both acid and salt media revealed that HEAs sintered at 1100°C exhibited the highest corrosion resistance, whereas those sintered at 700°C displayed the least resistance. The wear rate is improved by 130% over Inconel 718 alloy in the created HEA. This research signifies the potential of Ti20-Al16-V16-Fe16-Ni16-Cr16 HEA prepared through tailored SPS procedures, as corrosion and wear resistance alternatives surpass the performance of Ti6AlV4 and traditional alloys.

Semiconductive Tendency of the Passive Film Formed on Super Austenitic Stainless Steel SR-50A in Acidic or Alkaline Chloride Solutions

Stainless steel is widely used in various industrial fields due to its excellent corrosion resistance and mechanical properties. The key to this corrosion resistance is the thin passive film that naturally forms on the metal surface. Passive films are characterized by oxide film theory and adsorption theory, each uniquely explaining the structure and mechanism of the protective film on the metal surface. Research on the semiconductive properties of passive films on stainless steel offers diverse viewpoints, classifying theories into the point defect model and the bipolar fixed charge-induced passivity. Specific changes in passive film attributes that lead to degradation, however, are not fully understood. In this study, we analyzed the inner and outer layers of the passive film on super austenitic stainless steel SR-50A under various conditions in acidic and alkaline chloride environments. The interpretations of these results were based on the point defect model and the bipolar model for the passivation mechanism, and correlations between p-type and n-type semiconductor properties and passivation behavior were examined. The surface of the stainless steel forms a passive film comprising two layers with p-type and n-type semiconductive properties, independent of the pH of the solutions. The corrosion resistance increases as the p-type and n-type semiconductive tendencies become more balanced, consequently enhancing the properties of the passive film.

Anti-corrosion design of layered zirconium-based metal–organic frameworks (Zr-MOF) enhanced epoxy nanocomposite coatings

In this work, two-dimensional UiO-67 nanosheets are successfully modified on graphene oxide (GO). The synthesized GO@2D-UiO-67 composite not only exhibits the electrical insulation characteristics of Zr-MOF, but also leverages the passive barrier effect of its 2D layered structure to prepare a highly anticorrosive epoxy coating. Electrochemical measurements reveal that the impedance modulus of the GO@UiO-67/EP composite coating remain two orders of magnitude higher than that of the pure EP coating even after 28 days of immersion in 3.5 wt% NaCl solution. This good long-term anti-corrosion performance could derive from the enhanced crosslinking density of composite coating due to the incorporation of GO@UiO-67 nanosheets. Furthermore, the shielding effect of layered structure and the corrosion inhibition behavior of organic ligands are proved to improve the corrosion resistance properties of composite coating. This research fills the application void of two-dimensional Zr-MOF composites in resin coatings, as well as serves as a forward-looking initiative to enhance the long-term corrosion protection of epoxy resin coatings.

Duplex plasma electrolytic oxidation/ hydroxyapatite- polydopamine coating on WE43 alloy for bone implants: Long-term corrosion resistance and biological properties

This study aims to evaluate the corrosion behavior of WE43 alloy with plasma electrolytic oxidation (PEO)/hydroxyapatite (HA)-polydopamine (PDA) duplex coating. HA-PDA is co-deposited as the top layer using an electrodeposition process by varied dopamine hydrochloride concentration and deposition time following the PEO process. The findings show the development of a corrosion-resistant coating by regulating the surface morphology. Furthermore, long-term electrochemical impedance spectroscopy reveals that the total impedance of the optimized PEO/HA-PDA coating (deposition time = 10 min and dopamine hydrochloride concentration = 1 mg/mL) increased from 1720 Ω on day 1 to 14,600 Ω following 21 days of immersion. Co-deposited HA-PDA shows less hydrogen release and higher adhesion strength than PEO/HA samples. Finally, the PEO/HA-PDA coating is desirable for magnesium bone implants by considering the bioactivity of the coating resulting in improved cell-surface interaction.

In situ mildly synthesized CuZnAl LDHs nanofilm with long-lasting corrosion resistance and self-healing properties induced by corrosive Cl– ions

A smart means to achieve the harmless treatment of corrosive Cl– have been proposed for protecting brass. In this method, intelligent self-healing nanofilms based on the interlayer anion exchange properties of LDHs in situ grow on brass surfaces. The Cl– ions replace the BTA– loaded between LDHs interlayers to induce self-healing, as the binding energy of Cl– is lower than that of BTA–, obtained from theoretical calculations. The simultaneous application of electrochemistry and digital holography technologies confirmed that the constructed film has high instantaneous corrosion inhibition efficiency (99.9 %), long-lasting corrosion resistance, and self-healing ability (50 days).

Effect of pH on the controlled release of benzotriazole from halloysite clay nanotubes for corrosion protection of mild steel

Due to the increase in severe consequences of mild steel corrosion, the development of coatings with improvement in corrosion-resistant properties has become very essential. In this work, benzotriazole (BTA) was encapsulated into halloysite nanotubes (HNTs) for inhibiting the corrosion of mild steel surface. The BTA-encapsulated HNT exhibits pH-responsive properties over a wide range of pH. It was found that a large amount of BTA was released at pH 3 (48 %), followed by pH 7 (30 %) and least in the case of pH 10 (20 %). At neutral pH, a rapid release of BTA was observed during initial exposure, reaching a steady-state later, with no significant release further. A salt immersion test was carried out after immersing mild steel (MS) substrates in BTA-HNT nanopowder dispersion in 3.5 wt% NaCl at different pH. SEM images and EDS maps confirmed that corrosion product formation on MS surface at pH 3 was significantly more with corrosion pits along with HNTs throughout the surface. At pH 7 and 10, corrosion pits were observed with very few halloysite nanotubes on the surface. An optimum amount of BTA is required to inhibit corrosion, excessive release may cause more Cl− ions to penetrate, leading to more corrosion. Electrochemical data also reveals the same trend, where the icorr value was maximum for pH 3 (1.09 × 10−5 A/cm2) > pH 7 (4.74 × 10−6 A/cm2) > pH 10 (3.43 × 10−6 A/cm2). Therefore, results suggest that BTA-encapsulated HNT can be efficiently incorporated into the coating matrix for their controlled release to provide corrosion protection under varying neutral and alkaline marine environments.

Structure and Corrosion Behavior of Multiphase Intermetallic ZrCu-Based Alloys.

Zirconium-based alloys are highly regarded by the research community for their exceptional corrosion resistance, thermal stability, and mechanical properties. In our work, we investigated two newly developed alloys, Zr42.42Cu41.18Al9.35Ag7.05 and Zr46.81Cu35.44Al10.09Ag7.66, in the form of ingots and ribbons. In the course of our investigation, we conducted a comprehensive structural and thermal analysis. In addition, an examination of the corrosion activity encompassing electrochemical studies and an analysis of the corrosion mechanisms was carried out. To further evaluate the performance of the materials, tests of their mechanical properties were performed, including microhardness and resistance to abrasive wear. Structural analysis showed that both alloys studied had a multiphase, crystalline structure with intermetallic phases. The samples in the form of ribbons showed improved corrosion resistance compared to that of the ingots. The ingot containing a higher content of copper Zr42.42Cu41.18Al9.35Ag7.05 was characterized by better corrosion resistance, while showing lower average hardness and a higher degree of abrasive wear based on SEM observations after pin-on-disc tests.

Synthesis of MnFe2O4 Spinel on Rusted Q235 Steel Surface and Its Corrosion Resistance Properties.

Corrosion of steel is an issue that cannot be ignored in contemporary society. Due to large-scale corrosion, it is urgent to develop a surface treatment process that enhances the corrosion resistance of steel, allowing for application in various scenarios as needed. This study aims to investigate a novel surface treatment process to extend the service life of corroded Q235 steel, reduce its sensitivity to corrosion, and enable its use in multiple environments. This study employs the sol-gel method, using manganese nitrate solutions of varying concentrations to treat the surface of Q235 steel after different electrolysis times. The optimal conditions for precursor preparation were found to be a Mn2+ concentration of 0.1 mol/L and an electrolysis time of 2 h. Electrochemical tests using NaCl solutions of different concentrations revealed a significant reduction in the corrosion current for the composite coating based on Q235 steel treated with this method in NaCl solutions with wt.% = 1, 2, 3, 4, 5. Furthermore, the resistance to corrosion was strongest in the NaCl solution with a concentration of 1 wt.% where the corrosion current decreased from 24.8 µA/cm2 to 6.79 µA/cm2. Additionally, the coating was found to be diffusion-controlled in the early stages of the corrosion process and charge transfer-controlled in the later stages. The MnFe2O4 spinel coating demonstrated the greatest enhancement in corrosion resistance in the wt.% = 1 NaCl solution.

Enhancement of PEO-coated ZK60 Mg alloy: Curcumin-enriched mesoporous silica and PLA/bioglass for antibacterial properties, bioactivity and biocorrosion resistance

The corrosion resistance and antibacterial properties of ZK60 magnesium alloy implants have been enhanced via Plasma Electrolytic Oxidation (PEO) and electrospinning techniques. A robust, porous oxide coating was created on the ZK60 alloy using the PEO process, with characterization performed via SEM and XRD. Improved corrosion resistance of the PEO-coated samples was demonstrated through electrochemical analyses, including EIS and polarization tests. In addition to the PEO treatment, composite electrospun nanofibrous coatings were developed, incorporating curcumin-loaded mesoporous silica nanoparticles and bioactive glass. The electrospun nanofibers, which exhibited a diameter of 350 nm without beads, were characterized by Dynamic Light Scattering, Zeta Potential, Infrared Spectroscopy, BET, and XRD, confirming a curcumin loading of 10 wt%. Significant antibacterial activity against Escherichia coli and Staphylococcus aureus was shown by these fibers, and high bioactivity was observed after 14 days of immersion in simulated body fluid (SBF). The combination of PEO coatings and electrospun nanofibers highlights an enhancement in both corrosion resistance and antibacterial properties for implant applications.

Electrochemical performance of in-situ electrodeposited spinel-structured high entropy oxides/NiFeCuMoMn-high entropy alloy multiphase electrocatalysts for seawater electrolysis

Seawater electrolysis plays a pivotal role in advancing sustainable hydrogen production. High entropy alloys (HEAs), an innovative class of materials, have garnered significant attention for seawater electrolysis research in recent years due to their exceptional mechanical strength, catalytic efficiency, and corrosion resistance properties. This study presents the synthesis of a novel Ni-Fe-Cu-Mo-Mn based high entropy alloy catalyst featuring in-situ grown high entropy oxides (HEOs). This material exhibits HER overpotentials of η10 (Overpotential at 10 mA)=50.5 mV in 1 M KOH solution and η10 = 371 mV in natural seawater with a pH ≈ 8.2, after 50 h of Hydrogen evolution reactio (100 mA·cm−2), the η10 in seawater decreased from 371 mV to 343 mV. Demonstrates some autocatalytic capacity. Analytical results indicated that the HEOs/NFCMM (NiFeCuMoMn) -HEA surface is characterized by a spinel structure. The presence of this spinel-structured HEOs layer on the HEOs/NFCMM-HEA catalyst's surface enhances its ability to adsorb H2O effectively and facilitates the desorption of H* from non-acidic electrolytes, thereby significantly boosting the HER process.

Role of scandium addition to microstructure, corrosion resistance, and mechanical properties of AA7085/ZrB2+Al2O3 composites

The effect of varying amounts of scandium (Sc) on the mechanical performance and corrosion resistance of aluminum alloy (AA7085) composites reinforced with Zirconium diboride (ZrB2) and Aluminum oxide (Al2O3) nanoparticles was investigated. The specimens were made using an in-situ process with varying amounts of Sc up to 0.5 wt%, and their microstructural behavior, corrosion, and mechanical properties were explored in detail. Phase structural analysis revealed the successful incorporation of ZrB2 and Al2O3 into the matrix through in-situ synthesis, ranging from 30 to 61.7 nm. In addition, HRTEM and XRD analysis displays the Al3Zr prominence observed with 0.1 wt% Sc content, transforming to Al3(Sc, Zr) in the 0.3 wt% Sc composite, and finally becoming Al3Sc with 0.5 wt% Sc. Corrosion analysis revealed that the 0.3 wt% Sc composite exhibited fine Al3(Sc, Zr) precipitate phases that enhanced corrosion properties. The Sc addition leads to a significant improvement in the mechanical properties of AA7085/ZrB2+Al2O3 composites. The ultimate tensile strength of 678 ± 5 MPa for 0.5 wt% Sc under the hot rolled and T6 aged condition was achieved. The optimum content of Sc in AA7085/ZrB2+Al2O3 composites has identified both corrosion and mechanical properties enhancement at 0.3 wt% and 0.5 wt%, respectively.

Preparation and properties of multiphase composite enhanced functional organosilicon nano-coatings

BackgroundTo improve the inherent stability and environmental compatibility of traditional organosilicon coatings, nano-reinforced composite materials were innovatively designed and synthesized to improve the performance of organosilicon coatings. MethodologyThe silicon dioxide (SiO2) clusters on the surface of graphene oxide (GO) incorporated with calcium carbonate (CaCO3) and dicyclohexylamine nitrite (Dn) nanocomposites (GO@SiO2/CaCO3/Dn) were prepared successfully. Then nanocomposites were integrated into the coating matrix to comprehensively assess their effects on morphology, mechanics, corrosion resistance, and anti-fouling properties. Significant findingsScanning Electron Microscopy (SEM) observations revealed that 4.0 wt.% of the nanocomposite reinforcement led to stratification within the organosilicon coating. The mechanical properties test shows that the hardness, bonding strength, and maximum impact resistance of SiNC2.0 coating is 10.3 HV, 2.8 MPa, and 75 kg·cm, respectively. Electrochemical assessments confirmed that SiNC2.0 displayed superior corrosion resistance, with a corrosion potential (Ecorr) of 0.199 V and a corrosion current density (Icorr) of 7.308 × 10–6 A/cm2. Furthermore, the surface free energy of the nano-coatings is calculated in the range of 20–30 mN/m by contact angle measurement, indicating the anti-fouling and self-cleaning of the organosilicon nano-coatings. Long-term immersion in natural lake water further confirms the stability and durability of the SiNC2.0 coating in real environments.

Relaxation and crystallization of amorphous FeCrAlTiMo coatings: Effects on mechanical properties and lead-bismuth eutectic corrosion resistance

The microstructure evolution of amorphous FeCrAlTiMo coatings during annealing process, and the effects of structural relaxation and crystallization on its mechanical properties and LBE corrosion resistance are systematically investigated. With increasing annealing temperatures, three coatings with different microstructure, including relaxation and crystallization, could be obtained. The structural relaxation is beneficial to improve the LBE corrosion resistance of the coating, but it is accompanied by the loss of mechanical properties (interface bonding strength and wear resistance). The crystalline coating with multi-phase microstructure of BCC, FCC and HCP (<2％) exhibits the best LBE corrosion resistance and mechanical properties.

Superhydrophobic coatings prepared by spraying method with corrosion resistance and flame-retardant properties

In this study, aluminum tripolyphosphate (ATP) and silicon dioxide (SiO2) composites were introduced on the surface of copper sheets by spraying technique to prepare coating with flame retardant, superhydrophobic and corrosion resistant properties (ATP@SiO2). The coating not only exhibits excellent water repellency, but also has remarkable mechanical stability, with the corrosion current density reduced by an order of magnitude in electrochemical tests and the corrosion inhibition rate of 99.17 %. In flame retardant tests, the burning time of cotton fabrics coated with sprayed ATP@SiO2was extended by 38 s, with no smoldering observed. This study provides insights into the development of novel superhydrophobic materials with enhanced corrosion protection and flame-retardant properties.