Q235 Steel Substrate Research Articles

Corrosion Behavior of High-Pressure Cold-Sprayed Zn30Al Alloy Coating on Q235 Steel

This study employed a high-pressure cold spray to apply a Zn30Al alloy coating to Q235 steel substrates to provide corrosion protection for steel in marine environments. The corrosion resistance of the coatings was investigated through full immersion tests, and the corrosion mechanisms were further analyzed using electrochemical experiments. The results were compared with those of traditional flame-sprayed Zn30Al alloy coating. The findings indicate that the high-pressure cold-sprayed Zn30Al alloy coating possesses a dense microstructure with a porosity of only 0.32%, providing effective cathodic protection to the substrate during the immersion tests. The cold-sprayed Zn30Al alloy coating maintained good integrity after 720 h immersion in 3.5 wt.% NaCl solution, whereas the flame-sprayed Zn30Al alloy coating exhibited significant pitting corrosion.

Microstructure and wear behavior of WC-reinforced AlCoCrFeNiSi high entropy alloy coatings prepared by high-velocity arc spraying

In this study, AlCoCrFeNiSi/WC (WC from 0 to 40 wt%) high entropy alloys (HEAs) coatings were deposited on Q235 steel substrates using high-velocity arc spraying technique. The coatings' phases, microstructure, microhardness, nano-hardness, wear properties, and the mechanisms of wear were examined. The results have shown that the WC reinforced HEA had faced-centered cubic, body-centered cubic solid solution and carbide phases, while faced-centered cubic solution and Cr3Si, Al2O3 phase were observed in AlCoCrFeNiSi coating. The coatings possess a dense, lamellar structure and strong adhesion to the substrates. With the addition of reinforced particles, the porosity of the coatings initially decreases and then increases. The average microhardness of the coatings is significantly improved as WC content increased, reaching a maximum of 530 HV0.1. The ratio of nano-hardness to reduced elastic modulus rises as more WC is introduced. The coatings with the WC particles exhibit good wear resistance with the optimum wear rate at WC content of 40 wt%. Under the same conditions, the coating with 40 wt% of WC displayed the lowest wear rate, which decreased by 60.5 % compared to the AlCoCrFeNiSi coating. The AlCoCrFeNiSi coating experienced a mix of adhesive, abrasive, oxidative, and fatigue wear mechanisms. The wear mechanism changed to more abrasive, adhesive, and oxidative in the reinforced coatings. The load-bearing capacity and secondary phase strengthening effects of WC reduce the wear rate of the coatings.

Influence of Y2O3 content on the properties of Ni-Y2O3-MgO nanocomposite coatings prepared by pulse electrodeposition

This research examines the influence of yttrium oxide (Y2O3) nanoparticles as reinforcing particles on the microstructure and corrosion resistance of Ni-Y2O3-MgO composite coatings deposited by pulse electrodeposition. Varying Y2O3 contents are prepared on the Q235 steel substrate using the composite electrodeposition technology. The efficacy of the coatings was evaluated using a range of analytical methods, including SEM, EDS, XRD, wear investigation, and electrochemical testing. The results demonstrate that the incorporation of Y2O3 nanoparticles has a substantial effect on refining the grains of the composite coating, thereby improving its surface flatness and density. Particularly, the coating demonstrated the highest surface quality and the smallest particle size at 10 g/L Y2O3 content which may be associated with the fact that the high surface activity and large specific area of the Y2O3 nanoparticles promote the nucleation rate and inhibit the crystal growth during the deposition process of the composite coating. The presence of Y2O3 in the coating increased the self-corrosion potential and decreased the self-corrosion current density, thereby improving its corrosion resistance. Particularly, the composite coating containing Y2O3 at a concentration of 10 g/L exhibits the most effective resistance against corrosion. Furthermore, the inclusion of Y2O3 (10 g/L) effectively decreases the wear volume of the coating while simultaneously enhancing its hardness and wear resistance. This study provides a new way for the preparation and characterization of metal-based nanocomposite coatings.

Optimization design and interface characteristics research of high damping NiTi - Nickel-Aluminum Bronze functional gradient composite coating additively manufactured by high-speed laser-directed energy deposition

The near-equatomic NiTi shape memory alloy demonstrates exceptional damping performance due to its distinctive low-temperature self-cooperative martensitic internal friction. This study successfully fabricated NiTi-NAB (Nickel-Aluminium bronze shape memory alloy) functionally graded composite coatings with excellent metallurgical bonding between layers on Q235 steel substrates by designing an appropriate interlayer structure and employing the high-speed laser-directed energy deposition (LDED). Through comprehensive evaluation of the composite coating's performance and the numerical simulations of heat transfer within the molten pool, we elucidated the impact of process parameter levels on the microstructure and phase transformation characteristics of the NiTi alloy coating (NTC). The phase composition and phase interface characteristics of the NTC surface and bonding interface were analyzed using an electron probe microanalyzer and transmission electron microscopy, while dynamic thermomechanical analysis was employed to evaluate the damping performance of the NTC. The results indicate that an optimal parameter combination area still exists within the NTC-LDED process parameter window, even with equal laser energy density. Insufficient parameter levels can lead to an increase of micro-defects within the NTC, consequently causing a deterioration in both the cohesion and deformation resistance of the coating. Excessively high parameter levels can lead to significant element loss and residual stress, which in turn contributes to an increase in microcracks within the coating. A considerable quantity of reaction product mixture phases was formed at the interface between NTC and NAB, tending to align coherently with the NAB phase interface. The NTC, prepared with optimal process parameters, exhibits exceptional damping performance with a damping ratio of 0.498 at internal friction equilibrium, rendering it highly promising for applications in surface erosion protection for fluid machinery.

Controllable size of graphite nanosheets and functionalized SiO2 microspheres with excellent anti-corrosive/wear function for superhydrophobic coating

The application of superhydrophobic coatings is limited by their complex fabrication process, expensive modification, and lack of durability. This study addresses these issues by proposing a simple and economical method for fabricating strong superhydrophobic coatings by scraping off the fluorinated suspension. This coating comprises epoxy resin (EP), graphene nanosheets, and modified silicon oxide on the Q235 steel substrate. The contact angle and sliding angle of we prepare the coating coating are 152.3° and <10° respectively, exhibiting excellent super-hydrophobicity. After being immersed in 3.5 % sodium chloride solution for 1440 minutes, the coating shows a resistance of 1.14×106 Ω cm2, which is two orders of magnitude higher than that of the coating immersed for 30 minutes (1.08×104 Ω cm2), indicating its excellent corrosion resistance. A 30-day salt spray corrosion test also confirms the good corrosion resistance of the coating. When the coating is polished 100 times under a load pressure of 500 g on 1000-mesh sandpaper, the contact angle is only reduced by 7 times, indicating its good abrasion resistance. In addition, the coating also has good weather resistance and self-repairing ability against ultraviolet radiation. This simple and environmentally friendly manufacturing method has great potential for large-scale practical applications in many fields.

Microstructure and properties of WC-reinforced AlCoCrFeNiSi high entropy alloy coatings prepared via high-velocity arc spraying

In this research, (AlCoCrFeNiSi)100-x(WC)x (x=0, 20 and 40 wt%) high entropy alloy (HEA) coatings were successfully deposited on the surface of Q235 steel substrate using high-velocity arc spraying method. The study investigated the presence of WC particles on the phase composition, microstructure, tensile bonding strength, and corrosion behavior of the HEA coatings. X-ray diffraction analysis revealed that without WC particles, the predominant phase in the coating was a face-centered cubic (FCC). However, when 20 wt% and 40 wt% of WC particles were added, the phase composition shifted to include FCC, body-centered cubic (BCC), W3C, Cr7C3, and other carbides. The WC particles also reduced the crystalline grain size of the coatings from 14.75 nm to 10.34 nm. The microhardness value increased from 252.5 HV0.1 to a peak of 529.9 HV0.1, as the content of WC increased representing a microhardness improvement factor ranging from 1.4 to 3 times that of the substrate. The tensile bonding strength of the coatings was also enhanced with WC content. The coating with 40 wt% WC particles demonstrated the highest tensile bonding strength of 40.23 MPa. The cohesion, adhesion, and glue failures occurred after the tensile test, with adhesion failure being more prominent in the coatings without WC particles and glue failure being more prominent in the WC-reinforced coatings. Compared to the Q235 steel substrate, the coated samples showed enhanced resistance against corrosion due to the formation of the passive oxide layers. The effective resistance against corrosion was attained when the proportion of WC particles was 20 wt%, displaying the least values for corrosion current density and corrosion rate in 3.5 wt% NaCl solution. Examination through SEM and XPS analysis indicated that the coatings’ structures and the formation of protective passive layers enhanced the corrosion resistance.

Microstructure and hardness of CoNiCrFeTix high-entropy alloy coatings prepared by laser cladding: Combining experimental and molecular dynamics simulation

Laser cladding technology offers several advantages over alternative coating methods, including rapid cooling, low dilution rate, and effective metallurgical bonding between the coating and matrix. However, there is limited understanding regarding the microstructures and properties of laser-cladded high-entropy alloy (HEA) coatings. Thus, our research aims to investigate the characteristics and performance of CoNiCrFeTix (x = 0.1, 0.3, 0.5, 0.7) HEA coatings, produced through laser cladding, on Q235 steel substrates We employ molecular dynamics (MD) simulation and experimental techniques to examine the impact of Ti element content on the structure and hardness of the cladding layer. The MD simulation accurately reproduces the melting and nucleation processes of crystal structures, providing insights beyond what is observable through experiments alone. Our results reveal that the cladding layer is predominantly composed of an FCC phase, with an increasing presence of a BCC phase as the Ti content rises. Correspondingly, experimental observations confirm that the CoNiCrFeTix HEA coating primarily consists of the FCC phase, while FeCr, Ni2Ti, and Co2Ti phases emerge with higher Ti content.The cladding layer exhibits a characteristic dendritic (DR) structure, where the interdendritic (ID) region expands as Ti content increases. Additionally, we conducted surface hardness testing on the cladding layer. The hardness of the cladding layer increases with the increase of Ti content, and the increase in Ti content enhances the stability of the dislocation density in the cladding layer.

Dissolution behaviour of WC particles and evolution of precipitated phases in the plasma transfer arc Ni-based composite coating reinforced by 30 wt% WC particles

Ni-WC composite coating was prepared on Q235 steel substrate by plasma transfer arc (PTA) with welding current ranging from 70 A to 85 A. The results show that the dissolution behaviour of WC particles and the elemental diffusion at the interface promoted by the increased welding current promote the formation and evolution of precipitates, including M7(B, C)3 and M6C. The increased current reduced the volume fraction of WC particles in the coating, but increased that of the precipitates. At welding currents of 75 A and 80 A, dendritic-like M7(B, C)3 presented a regular distribution at the bottom of the coating. At a welding current of 80 A, M6C phase began to form at the bottom of the coating. When the welding current reached 85 A, the dendritic structure was broken, and the M6C phase aggregated and grew. The Ni-WC coating had visible delamination. WC particles at the upper part of the coating dissolved more severely compared to those at the middle and bottom of the coating. Ni3Si compound was formed at the upper and middle of the coating, and it had a crystal orientation relationship of [011]Ni3Si∥[011]γ-Ni, (11-1)Ni3Si∥(11-1)γ-Ni, (−200)Ni3Si∥(-200)γ-Ni, (-11-1)Ni3Si 1.3° from (-11-1)γ-Ni with γ-Ni. The average hardness of the coating decreased slightly due to the dissolution of WC, but the hardness at the interface increased, showing an improved bonding of the interface. The newly formed high hardness precipitates can share the load coming from the friction paired ball, thus reducing CoF and wear loss of the coating.

Micro-structures and dry sliding wear properties of novel AlCrFeNiMo0.5-x(WC) high entropy alloy-ceramic composite coatings

Based on the problems of micro defects (cracks, pores, etc.), uneven distribution of strengthening particles, and poor bonding between strengthening particles and metal matrix in practical engineering applications, the new AlCrFeNiMo0.5-x(WC) (x = 0, 5, 15, 30 wt%) composite coatings have been designed, and further prepared using laser cladding. Their micro-structures, micro-hardness and dry sliding wear properties were deeply explored. They exhibited the dendritic morphologies and consisted of BCC1, BCC2, and carbide phases. The AlCrFeNiMo0.5-30 wt%(WC) coating had the highest hardness (772 HV), which was approximately 5 times that of Q235 steel substrate. With the increase of WC content, dry sliding wear properties showed an increasing trend, that is, AlCrFeNiMo0.5-30 wt%(WC) coating had the lowest friction coefficient (0.50) and wear rate (9.23 × 10−6 mm3/(N · m)), exhibiting excellent tribological properties, which was attributed to the coupling effect of hard carbide and ductile BCC phases. It would be a promising wear-resistant coating material under dry sliding environment. This study not only has significant theoretical significance for understanding the failure patterns and performance evolution of new high entropy alloy/WC composite coating materials in dry sliding environments, but also demonstrates important value for expanding the application of new high entropy alloy/WC composite coating materials in practical engineering.

Parametric optimization corrosion erosive wear and XPS response of FeCrCoAlTiB and FeCrCoNiSiB coatings on Q235 steel substrate by HVOF spraying using taguchi method

In the study high-velocity oxy-fuel thermal spraying to create Fe32Cr21Co21Al16Ti5B5 and Fe43Cr16Co12Al14Ti5B10, Fe32Cr21Co21Ni16Si5B5 and Fe43Cr16Co12Ni14Si5B10 coatings on Q235 steel substrates. Jet-type testing is used to examine the coatings’ resistance to slurry wear. Researchers examined the surface to learn more about the erosion process. Taguchi analysis and a wear model confirm the significance of the selected important factors. The wear model’s proposed mechanism shows remarkable agreement with the data. Coating loss may be attributed to several causes, including mixed ploughing, and cutting, platelet development, abrasion grooves, and cracking. The outcomes showed that the effect speed was the main contributing variable, the contribution ratio reached 65% to 70%, for the impact velocity of coating no 1 to 4. In contrast, it is recognized that impact velocity > impingement angle > erodent feed rate > erodent size is the most important sequence. Micro-cutting, mixed cutting, and ploughing were the essential disintegration systems for all coatings at low impingement points. In contrast, platelets were detected under normal impingement angles, as confirmed by SEM analysis. Both coatings seem to form passivation films, as shown by their greater Ecorr values relative to the substrate. Fe, Co, Cr, Al, and O all show up as peaks in XPS analyses.

Corrosion Performance of Epoxy/Sulfur–Selenium Coating on Q235 Steel

Sulfur powder (99.99%) and selenium powder (99.99%) were mixed and heated to approximately 300 °C to obtain an S-Se alloy. It has good flowability at 130 °C and can be applied to Q235 steel to obtain a S-Se coating. Epoxy was used as a filler, and the S-Se alloy was applied as a coating. This combination was utilized to create the composite coatings of epoxy/sulfur–selenium (E/S-Se). To investigate the corrosion resistance of this coating on Q235 steel substrate, we conducted measurements and obtained electrochemical impedance spectra (EIS) and linear polarization curves (LPC). These measurements were performed in a three-electrode cell within an electrochemical workstation using a 3.5 wt.% NaCl aqueous solution. By comparing bare Q235 steel, S-Se, and E/S-Se, the study found that the E/S-Se coating had a higher self-corrosion potential (−0.484 V vs. SCE) and the lowest self-corrosion current density (2.361 × 10−11 A/cm2). The purpose was to simulate the corrosive environment experienced by condensate return pipe walls in petroleum refining equipment. Additionally, experiments were carried out using 0.01 mol/L HCl solution as the corrosion medium at different temperatures (40 °C, 60 °C, 80 °C). The results indicated that the E/S-Se coating exhibited a lower corrosion rate compared to the Q235 steel substrate. Under immersion conditions at 40 °C and 60 °C, no corrosive substances were detected on the surface of the coating. The test results demonstrated that the E/S-Se coating exhibited superior corrosion resistance compared to the Q235 substrate, providing up to 99% protection for the substrate.

The Effect of Plasma Spray Parameters on the Quality of Al-Ni Coatings

The plasma spray method is widely utilized for enhancing wear, surface fatigue, and corrosion properties through coating. The mechanical and surface characteristics of the resulting coating are contingent upon various spraying parameters, including arc current, working current, spraying distance, and plasma gun traversing speed. This study investigates the impact of these manufacturing parameters on the porosity, hardness, and bond strength of a coating produced from an Al-Ni alloy applied to a Q235 steel substrate. An extensive experimental program was conducted to analyze the influence of these parameters on the coating properties. Consequently, a preferred combination of parameters, identified through a comprehensive evaluation method, yielded greater performance benefits compared to the orthogonal experimental groups.

Investigation of tensile fracture mechanism of Fe-based coatings deposited on different substrates by arc spraying

The adhesion strength of the coating to the substrate determines the service life and performance of components coated by thermal spraying. FeCrMoCBWNb coatings were deposited via arc spraying process to study the adhesion properties of the coatings on Q235 and 65Mn steel substrates. The adhesion properties and tensile fracture mechanisms of the coatings on different substrates were examined by the tensile bonding strength. The phase intensity and crystallinity of the coatings were studied by X-ray diffractometer (XRD). The microstructure and mechanical properties of the coatings were also characterized. The adhesion properties of the coatings depended on the substrates' mechanical properties. The tensile bonding strengths of the coating on Q235 and on 65Mn were 45.5 ± 5.4 MPa and 40.8 ± 1.4 MPa, respectively. The higher substrate roughness of the Q235 steel enhanced the mechanical interlocking of the coating particles to the substrate. The tensile fracture of the coatings comprised brittle and ductile fracture mechanisms.

Electrodeposition-hydrothermal synthesis of inhibitor anion-intercalated layered double hydroxide films for corrosion resistance on steel substrates

The in-situ growth of layered double hydroxide (LDH) film on steel substrates holds huge potential for corrosion protection in reinforced concrete. However, because steel will passivate in alkaline environments, almost only CO32−-LDH films can be grown in situ on carbon steel surfaces at present, limiting the ability of LDH to release inhibitory anions. In this study, we proposed a novel electrodeposition-hydrothermal method to grow Mg/Al-NO3−-LDH films in situ on Q235 steel substrates. Subsequently, CO32−, PO43−, and V2O74− anion-intercalated LDH films were successfully prepared through anion exchange to enhance their functional applications. All LDH films were dense, uniform, and exhibited good adhesion to the substrate, with a thickness of approximately 20 μm. The electrochemical results demonstrated a significant improvement in the corrosion resistance of the steel containing LDH films. Specifically, the LDH films with intercalated inhibitory PO43− and V2O74− anions exhibited corrosion protection efficiencies exceeding 97.37 % in 3.5 wt% NaCl solution and 99.99 % in simulated concrete pore solution with chlorides.

Optimization of the Forming Quality of a Laser-Cladded AlCrFeNiW0.2 High-Entropy Alloy Coating

Laser cladding is an effective surface strengthening method widely used in the surface treatment of extreme operating components such as gas turbines, aviation engines, and nuclear facilities. However, traditional cladding layers struggle to meet the diverse application needs of extreme working conditions due to their single cladding material and poor forming quality. Therefore, this article selected the new-type high-entropy alloy as the coating material and optimized its laser cladding process parameters in order to obtain an AlCrFeNiW0.2 high-entropy alloy coating with an excellent forming quality. It was found that as the laser power increased from 300 to 1800 W, the AlCrFeNiW0.2 high-entropy alloy coating transitioned from the incomplete or near-melted state to the fully and over-melted state gradually, while the coating showed the opposite trend of change as the laser scanning speed increased from 0.002 to 0.008 m/s. And when the laser power was 1000 W, the scanning speed was 0.005 m/s, and the spot diameter was 0.003 m, the AlCrFeNiW0.2 high-entropy alloy coating with a low dilution rate (9.95%) had no defects such as pores and cracks, and achieved good metallurgical bonding with Q235 steel substrate, demonstrating excellent forming quality. These could provide valuable theoretical and technical guidance for optimizing the laser cladding process and forming quality of new-type high-entropy alloy coatings.

A new type of high hardness coating for improving drill bit stability in unconventional oil and gas development

In deep unconventional oil and gas development, the problem faced is that PDC bits are eroded by solid-liquid high-speed fluids, resulting in damage. It has led to serious damage to the stability of the drill bit, a decrease in the service life of the drill bit, and an increase in the difficulty in efficient drilling. The essence is that the surface hardness and erosion resistance of the drill bit are not strong enough. Therefore, improving the stability of drill bits is a crucial and urgent problem to be solved. In this paper, Ni60A + 20% WC + 0.3% graphene composite coatings were prepared on a Q235 steel substrate, which is a new type of high hardness coating. Moreover, the effects of microstructure and microhardness of the composite coatings at different laser powers (800 W, 1200 W, 1600 W, and 2000 W) were investigated. The results show that the laser power can significantly affect the microstructure of the coating. The phase composition of the composite coatings is essentially the same at different laser powers. However, there are significant differences in the content of each phase. When the laser power is higher than 1200W, the content of M23C6, Cr3C2 and Fe3C in the composite coating increases and the microhardness of the coating decreases. When the laser power is below 1200 W, the dilution rate of the substrate is low and a metallurgical bond cannot be formed between the composite coating and the substrate.

Performance of Ni–SiC composites deposited using magnetic-field-assisted electrodeposition under different magnetic-field directions

To improve the surface and structure performances of metal parts, magnetic-field-assisted electrodeposition was applied to deposit the Ni-SiC composites on Q235 steel substrates. The surface morphology, roughness, microstructure, abrasion resistance, and corrosion resistance of the composites were investigated by scanning electron microscopy (SEM), transmission electron microscopy (TEM), atomic force microscopy (AFM), X-ray diffraction (XRD), hardness and friction wear tests, and electrochemical analysis, respectively. The Ni-SiC composite (MC-1) fabricated at 0.5 T with perpendicular magnetic direction exhibited a smooth, dense, and fine surface morphology, the highest SiC content, and a Ni grain size of only 72.3 nm. Furthermore, AFM images showed that the roughness of the MC-1 composite (Ra of 84 nm) was lower than those of Ni-SiC composites deposited at 0 T and 0.5 T. XRD analysis indicated that the application of a perpendicular magnetic field changed the preferred growth of Ni grains from the (200) to (111) crystal plane. MC-1 had the highest microhardness and lowest friction coefficient of all composites, indicating its superior abrasion resistance. Furthermore, the MC-1 composite had the lowest corrosion current (0.466 μA/cm2) and highest corrosion potential (−254 mV), indicating its superior corrosion resistance compared to the other composites.

Microstructure and corrosion behavior of Co-free FeCrNiSi0.4 medium entropy alloy coating fabricated by laser cladding

To improve the performances of engineering components is a hot topic for materials science and engineering communities. In the present work, the Co-free FeCrNiSi0.4 medium entropy alloy (MEA) coating was manufactured onto a Q235 steel substrate using laser cladding. Then, the microstructure, hardness and corrosion resistance of the MEA coating were carefully examined. The results indicate that the MEA coating, without obvious cracks and pores, exhibits a duplex phase microstructure consisting of majority face-centered cubic (FCC) phase and minor hexagonal close-packed (HCP) phase. In 3.5 wt% NaCl solution, the MEA coating displays superior corrosion resistance with a pitting potential of 1.19 V (vs. SCE), which is much higher than that of 304 stainless steel. The remarkable anti-corrosion performance can be attributed to the multiple kinds of oxidation (NiO, Fe2O3, Cr2O3 and SiOx (x < 2)) formed on the passive film and the small difference of Volta potential (∼40 mV) between FCC phase and HCP phase. Moreover, the microhardness of the coating reaches 346 HV, which is 2.1 times higher than that of the Q235 steel. These findings offer an effective route to fabricate a MEA coating with superior corrosion resistance and mechanical property, which thus can improve the service stability of industrial components.

Interesting ‘island-like’ microstructure and tribological evaluation of Al1.5CrFeNiWTi0.5 high entropy alloy coating manufactured by laser cladding

Al1.5CrFeNiWTi0.5 high entropy alloy coating with interesting ‘island-like’ microstructure containing BCC and Laves phases was designed and produced on Q235 steel by laser cladding. Its hardness was 880 HV, which was about 6.4 times that of substrate. The tribological properties of Q235 steel substrate were greatly improved by Al1.5CrFeNiWTi0.5 coating, which had the lowest friction coefficient (0.26) and wear rate (5.15 ×10−7 mm3/(N·m)) in deionized water. This was mainly attributed to the hydrolysis and oxidation reactions of coating surface material. The reaction products could improve bearing capacity and isolate the direct contact of coating and coupled ball effectively, resulting in a decrease of firction and wear. The Al1.5CrFeNiWTi0.5 coating would become a promising choice of wear-resisting material under water-lubricated environment.

Heat Stability and Icing Delay on Superhydrophobic Coatings in Facile One Step.

Superhydrophobic coatings are limited to poor durability and a tedious preparation process. In this work, an efficient, eco-friendly, and cost-effective sol-gel method is developed for preparing superhydrophobic surfaces using an all-in-one suspension composed of methyltrimethoxysilane (MTMS), nano silicon dioxide (SiO2) particles, and micron zinc oxide (ZnO) particles. Superhydrophobic coatings with a contact angle (CA) up to 153.9° and a sliding angle (SA) of about 3.0° are prepared on Q235 steel substrates using MTMS 5 mL, 0.8 g of nano SiO2, and 0.2 g of micron ZnO. The morphology of the superhydrophobic coating is characterized by scanning electron microscopy (SEM), and the surface is covered with a micro- and nano-scaled hierarchical rough structure. A series of tests are conducted, including long-term stability tests and thermostability tests. The CAs are all above 150°, and the SAs are below 6.3°, indicating the excellent static stability of the prepared superhydrophobic coatings. Moreover, the CA of the superhydrophobic coating remains above 152° after 120 h of UV exposure, and the time for a water droplet to freeze on the surface of the superhydrophobic coating is 18 times of the bare Q235 steel, indicating that the superhydrophobic coating exhibits good resistance to UV radiation and icing-delay properties.