Spray Technology Research Articles

Highly Transparent and Superhydrophobic SiO2 Coating with Nanoscale Structures by One-Step Spraying Technology for Applications as Self-cleaning Coatings

Highly Transparent and Superhydrophobic SiO₂ Coating with Nanoscale Structures by One-Step Spraying Technology for Applications as Self-cleaning Coatings

Multilayer Bionic Tunable Strain Sensor with Mutually Non‐Interfering Conductive Networks for Machine Learning‐Assisted Gesture Recognition

AbstractFlexible strain sensors capable of acquiring tiny mechanical signals and attaching to various irregular surfaces are becoming prevalent in physiological measurement, soft robotics, and human‐machine interaction. However, the advancement of flexible strain sensors is substantially impeded by the intrinsic compromise between sensitivity and the range of detectable signals. Inspired by the multilayer structure of nacre in nature, a carbon nanotubes (CNTs)/graphene (GR)/graphene (GR)/thermoplastic polyurethane (TPU) mat (CGGTM) is prepared by electrospinning and high‐pressure spraying technology. By designing a multilayer structure with mutually non‐interfering conductive networks, the resulting CGGTM possesses a low detection limit (0.05% strain), high sensitivity (gauge factor, GF > 152537), large detection range (up to 364% strain), fast response/recovery time (80 ms/100 ms), and excellent cyclic durability (up to 1000 cycles). Furthermore, the CGGTM also exhibits satisfactory triboelectric performances when assembled into a triboelectric nanogenerator (TENG, 3 × 3 cm2), including high triboelectric output (open‐circuit voltage Voc = 135.4 V, short‐circuit current Isc = 1.25 µA) and power density (88 mW m−2), enabling reliable power supply, self‐powered sensing, and pulse monitoring capability. Finally, CGGTM is successfully applied to the collection of biological signals and multi‐gesture motion recognition assisted by machine learning algorithms, which holds promise for intelligent interaction with gestures in the future.

Structural characteristics and evolution in the crack propagation process of NiCrAlY/YSZ gradient coatings through thermal shock at 900 °C

In this study, four different thicknesses of NiCrAlY/8YSZ gradient coatings were fabricated using atmospheric plasma spraying (APS) technology. The failure behavior and lifetime of coatings were subsequently compared and analyzed through thermal shock experiments. The results revealed a pronounced correlation between the initiation and propagation of internal cracks within the gradient coatings and the thickness of the gradient region at a thermal shock temperature of 900°C. Both horizontal and vertical cracks were observed to propagate and interconnect, with horizontal crack propagation being the primary cause of coating failure. Notably, samples featuring a gradient region thickness of 150μm exhibited superior thermal shock resistance, suggesting promising prospects for enhanced coating durability.

Microbial Inoculants Modify the Functions of Resident Soil Microbes to Expedite the Field Restoration of the Abandoned Mine

ABSTRACTGlobal‐scale mining activities have had significant deleterious impacts on local ecosystems and the overall environment, which will necessitate robust restoration efforts. A practical approach includes combining microbial inoculants with the technology of external soil spray seeding. This approach holds the potential for sustainable abandoned mine site restoration by enhancing plant growth through the modulation of soil nutrients and microbial communities. Nonetheless, the detailed effects of microbial inoculants on specific aspects of soil microbial community functions and their complex interactions with plant growth remain underexplored, particularly in the context of restoration efforts. To bridge this gap, we performed a four‐year field study at an abandoned carbonate mine location, using metagenomic sequencing to evaluate the influence of microbial inoculants on soil microbial functionality. Our research revealed that introducing microbial inoculants greatly enhanced essential soil parameters and notably increased plant biomass. Additionally, these inoculants altered the functional gene makeup of the microbial community, significantly boosting the relative abundance of processes such as nitrogen fixation, nitrification, denitrification, assimilatory nitrate reduction (ANRA), dissimilatory nitrate reduction (DNRA), and organic phosphorus mineralization. Conversely, there was a decrease in the relative abundance of carbon degradation, phosphorus regulation, and transport processes. We observed strong correlations between the abundance of nitrogen and phosphorus cycles and plant biomass. Crucially, microbial inoculants affect plant biomass by initially altering soil properties and subsequently coordinating nitrogen and phosphorus cycles. These findings provide valuable insights into the role of microbial inoculants in mine site restoration and offer a theoretical foundation for their broader practical application.

Agent-based modeling system for real-time characterization of film thickness in digital twin coating

In the automated spraying workshop of ship segments, poor visibility caused by dust and fog hampers the effectiveness of the video monitoring system. The traditional method used during the automated spraying process fails to provide real-time measurement of film thickness and prediction of spraying quality, resulting in uneven film thickness and high rework rates. Robotic spraying technology also faces challenges, such as the time-consuming and labor-intensive process of building and computing a highly reliable Computational Fluid Dynamics (CFD) based spraying film-forming simulation model, which cannot be reflected in real-time during the spraying process. The digital twin characterization method, based on the agent model, offers a solution to these limitations and challenges, providing new ideas and approaches for improving and optimizing the spray film formation model. This paper presents the development of a real-time characterization system for sprayed film thickness based on digital twin technology. The spraying film thickness under different working conditions is obtained using Ansys-Fluent simulation software by varying the gun height and gun speed. The predictive model for spraying film thickness is then established using the obtained simulation data and the corresponding gun height and gun speed, employing the surrogate modeling method (BP neural network). The real-time characterization system for spraying film thickness is developed by combining C# and Unity3D. Finally, in order to ensure the accuracy of the predictive model, a spraying experimental platform is built to verify the accuracy of the predictive model.

Fabrication and Tribology Properties of PTFE-Coated Cemented Carbide Under Dry Friction Conditions

PTFE coatings were deposited on YT15 carbide substrates using spray technology. A series of examinations were conducted, including the use of surface and cross-section micrographs to analyze the structural integrity of the coatings. The surface roughness, the adhesion force between the PTFE coatings and the carbide substrate, and the micro-hardness of the coated carbide were also evaluated. Additionally, the friction and wear behaviors were assessed through dry sliding friction tests against WC/Co balls. The test results indicated that while the PTFE-coated carbide exhibited a rougher surface and reduced micro-hardness, it also demonstrated a significant reduction in surface friction and adhesive wear. These findings suggest that the PTFE coatings enhance the overall wear resistance of the carbides. The lower surface hardness and shear strength of the coatings influenced the friction performance, leading to specific wear failure mechanisms, such as abrasion wear, coating delamination, and flaking. Overall, the deposition of PTFE coatings on carbide substrates presents a promising strategy to enhance their friction and wear performance. This approach not only improves the durability of carbide materials but also offers potential applications in industries where reduced friction and wear are critical for performance.

Enhanced Anti-Corrosion and Biological Performance of Plasma-Sprayed Nb/ZrO2/HA Coatings on ZK60 Mg Alloy

Niobium (Nb) and zirconium dioxide (ZrO2) were doped into hydroxyapatite (HA) to fabricate HA-based composite coatings prepared on a ZK60 magnesium alloy by plasma spraying technology to improve anti-corrosion and biocompatibility for clinical applications. The results revealed that the Nb-enriched coating exhibits fewer cracks and pores with a flat surface due to the decreased temperature gradient during spraying, and small needle-like structures can fill the cracks and pores in the ZrO2-contained coating, resulting in a more uniform and dense surface. Compared to coatings with only niobium or zirconium dioxide, the ZrO2/Nb/HA composite coating significantly enhanced the mechanical properties and corrosion resistance of the magnesium alloys. Among all the specimens, the ZrO2/HA coating and ZrO2/Nb/HA coating revealed high surface hardness values (327.73 HV and 293.80 HV, respectively). However, the higher hardness value made the ZrO2/HA coating fragile and more likely to crack, while the ZrO2/Nb/HA coating avoided this shortcoming and exhibited a more comprehensive performance. During immersion tests, the ZrO2/Nb/HA coating exhibited a gradual pH increase and minimal mass loss, and the cytocompatibility test demonstrated promising cellular activity.

Improving thermal shock and oxidation resistance of Cr3C2/WC-NiCr cermet coating by embedding large NiCrAlY superalloy particles

Cr3C2/WC-based cermet coating is widely used on the surface of mechanical equipment to strengthen its wear and corrosion resistance. Improving the high-temperature performance of cermet coating is the key to its industrial application. In this study, a novel type of bimodal microstructure cermet coating with the design of functional sites was fabricated via high-velocity air fuel (HVAF) spray technology. The toughness NiCrAlY superalloy particles are introduced into the traditional Cr3C2/WC-NiCr cermet structure to construct the thermal stress release site, which significantly improved the thermal shock resistance and thermal oxidation properties of the coating. The addition of NiCrAlY superalloy particle reduces the porosity of Cr3C2/WC-NiCr coating to 0.29 % and creates high-quality interface bonding and surface passivation layer. The newly structured cermet coating exhibits outstanding high-temperature performance. In a 1000 °C oxidation environment, the new coating remained intact after 120 h of exposure, while the traditional Cr3C2/WC-NiCr cermet coating exfoliated completely after 48 h of exposure. Further, in the thermal shock condition at 1000 °C, the lifetime of the new coating is 50 times greater than that of the traditional cermet coating, displaying excellent ability to relieve thermal stress. Additionally, the new coating shows good wear resistance and stability during high-temperature thermal exposure. After thermal exposure for 24 h and 72 h, the wear rates of the coating are 5.28 and 5.83 × 10−5 mm3 N−1 m−1, respectively, which is slightly lower than that of the as-sprayed coating. This study provides guidance for the improvement of high temperature resistance of thermally sprayed Cr3C2/WC-based cermet coatings.

Preparation process, surface properties and mechanistic study of HVAF-sprayed CoCrFeNiMo0.2 high-entropy alloy coatings

The objective of this study is to develop infrared reflective coatings with excellent service performance in extreme environments, aimed at reducing system energy consumption and enhancing service life. In this work, CoCrFeNiMo0.2 high-entropy alloy (HEA) powder was deposited on the 316 L stainless steel (SS) substrate using High-Velocity Air Fuel (HVAF) thermal spray technology. The microstructure, mechanical properties, infrared reflectivity, and corrosion resistance of the coatings under different spraying parameters were investigated and compared with those of the substrate. Computational Fluid Dynamics (CFD) simulation was employed to analyze the influence of HVAF spraying parameters on flame characteristics and particle flight behavior, providing guidance for optimizing the spraying process and explaining underlying mechanisms. Results demonstrated that adjusting parameters such as propane and air pressure, spraying distance, and powder feed rate could produce dense coatings with <1 % porosity. The microhardness of the coatings was approximately 1.8 times that of the substrate, and the bonding strength between the coating and the substrate is increased to 39.4 MPa. Additionally, the near-infrared reflectivity of the coatings was significantly higher than that of the substrate, with an enhancement of 18.7 %. Coatings sprayed under different parameters exhibited superior passivation and pitting corrosion resistance compared to the substrate in 3.5 wt% NaCl and 1 mol/L HCl solutions. Optimization of spraying parameters further enhanced the protective capability of the passivation film and corrosion resistance. Consequently, CoCrFeNiMo0.2 HEA coatings prepared by HVAF spraying technology demonstrate excellent comprehensive performance, holding promising potential for industrial applications.

A comparison of cold spray, atmospheric plasma spray and high velocity oxy fuel processes for WC-Co coatings deposition through LCA and LCCA

In this study, an environmental and economic assessment of WC-Co coatings deposited by Cold Gas Spray (CGS), Atmospheric Plasma Spray (APS) and High Velocity Oxy Fuel (HVOF) spray technologies is carried out. Using SimaPro LCA software, several environmental impact categories are analyzed to compare their environmental performance. The economic analysis includes capital and operating expenditures. The results have highlighted that all three processes exhibit low environmental impact in terms of CO2 emissions but the performance of the CGS process is heavily influenced by the low deformability of WC-Co, while the APS process is affected by high electricity consumption. In terms of economic analysis, the HVOF process exhibits the best performance, while the CGS process requires most time to deposit the coating, and consequently, it is the process where the workforce component is most significant. These results depend on the fact that CGS might not be the most suitable deposition technique for fabricating WC-Co coatings.

Microstructure and properties of plasma sprayed NbC-Al2O3 composite coatings

Niobium carbide has received widespread attention due to its high melting point, high strength, high chemical stability and high wear resistance, but the current preparation of niobium carbide coatings using plasma spraying technology suffers from low deposition efficiency, poor fusibility of the composite powders, high porosity, and high defects in the coating microstructure. Therefore, the microstructure and properties of NbC-Al2O3 composite coatings prepared by plasma spraying NbC-Al2O3-SiC composite powder and reactive plasma spraying Nb2O5-SiC-Al composite powder were comparatively investigated in this paper. The reaction mechanism of Nb2O5-SiC-Al composite powder during plasma spraying as well as the mechanism of the formation of coatings were analyzed in detail. The results showed that compared with the ex-situ NbC-Al2O3-SiC coating fabricated by plasma spraying, the in-situ Nb2O5-SiC-Al composite coating prepared by reactive plasma spraying had an obvious layer structure, low porosity (5.8%), high hardness (1141 HV0.1), high toughness (22.94 J/m2), and good scratch resistance properties.

The investigation of support effect from hard substrate to soft coating of PI/EP-PTFE under different coating thicknesses and frictional contacts

Engine bearings on ships can experience rapid failure under extreme conditions, such as when seawater infiltrates the engine compartment due to collisions with reefs or missile attacks. To enhance the self-lubrication and wear resistance of these bearings, a composite coating consisting of ZrO2-PI/EP-PTFE has been designed. This coating was applied using liquid spraying technology onto the surfaces of A370 aluminum alloy, CuPb22Sn2.5 copper alloy, and 15# carbon steel. Three different coating thicknesses—20 μm, 30 μm, and 40 μm—were applied to each substrate. The tribological properties of these coatings on the three substrates were investigated under both dry sliding wear and seawater corrosion conditions. The results indicated that the tribological performance of the coatings is influenced by factors such as the coating hardness, frictional contacts, and the supporting effect of the substrate. The hardness and elastic modulus of the coatings decreased as the coating thickness increased. A thicker coating results in reduced support from the substrate. The adhesive wear of these coatings under dry sliding wear conditions on the different substrates is also presented. The coefficients of friction (CoFs) of these coatings increased with coating thickness on all three substrates. In contrast, the wear rates decreased as the coating thickness increased. The hardness of the coating was influenced by the support effect of the substrate. The primary factors governing the tribological performance of the coating under dry sliding conditions are the pinch action of the hard grinding ball against the soft coating on the hard substrate and the contact pressure. Abrasive wear, spalling wear, plough grooves, and spalling pits were observed under seawater corrosion conditions. These findings suggest that increased coating thickness is associated with lower coefficients of friction (CoFs) and wear rates. The main contributing factors are seawater corrosion and the scouring effect of high-frequency reciprocating friction.

Driving sustainability in the sugarcane industry: Life Cycle Assessment of conventional and emerging spraying technologies in Tanzania

Sugarcane dominates global sugar and bioethanol production, involving extensive cultivation and supply chain activities. The sugarcane development encounters challenges, such as climate change, diseases, pests, and water scarcity, affecting growth and yields. Sugarcane management often involves the use of pesticides, which risk soil and water contamination. It also leads to biodiversity loss, high water use, greenhouse gas emissions, and energy consumption. This study conducted a life cycle assessment to compare the environmental impacts of cropdusters and drones in ripener application for sugarcane farming. The life cycle assessment enables informed decisions on sustainable practices by providing a holistic view of environmental impacts, facilitating comparisons, and identifies hotspots. The analysis examined the impacts of machinery, ripener compounds, and spraying operations. It explored using sugarcane waste (bagasse) as bioenergy for drone batteries or cropdusters. Results show that drones minimize environmental impacts by 11,557 kgCO2eq, 128,079 MJ, and 103 m3 for 40 ha farm compared to using cropdusters. Also, bagasse from a 40-ha farm can generate 1.93E+09 Wh of bioenergy, enough to charge drone batteries for spraying over approximately 4.9 million ha or to fuel cropdusters for 0.04 million ha of sugarcane. Conclusively, emerging technologies help to reduce environmental impacts and align with sustainable development goals, SDG 7 (Affordable and Clean Energy), SDG 9 (Industry, Innovation, and Infrastructure), SDG 12 (Responsible Consumption and Production), and SDG 15 (Life on Land). These goals promote renewable energy, enhance agricultural efficiency, and ensure sustainable resource management, fostering a global transition to sustainable practices.

Effect of ethanol addition on enhancing the cooling performance improvement of spray system

The widespread application of spray technology has significantly improved outdoor environmental thermal comfort. However, the spray system is unable to fulfill special comfort requirements. Utilizing mechanical ventilation and control systems effectively enhances the cooling performance of spray systems; however, those approaches are associated with elevated costs and maintenance complexities. The combination of ethanol and water has been demonstrated to produce a lower surface tension and a higher latent heat of evaporation, a property that contributes to the heat transfer efficiency and evaporation rate of the droplets. Considering the convenience and cost-effectiveness of adding ethanol as an additive, it emerges as the optimal choice. To evaluate the effectiveness of ethanol on the evaporative cooling performance of the spray system, a comparative study was conducted, comparing the cooling performances of different concentrations of ethanol with a spray system without ethanol addition. Five operating conditions were designed, including a no-spray case, a non-additive case, a 0.5% ethanol concentration case, a 1.0% ethanol concentration case, and a 1.5% ethanol concentration case. The results demonstrated that adding ethanol effectively enhanced the cooling performance of the spray system. At 1.7m above ground level (0.4m away from the nozzle), compared to the non-additive case without ethanol, the 0.5% ethanol concentration case, 1.0% ethanol concentration case, and 1.5% ethanol concentration case further reduced the temperature by 0.95°C, 1.64°C, and 2.27°C. Moreover, the relative humidity grew by 3.57%, 9.25%, and 13.5%, respectively. Adding ethanol significantly enhanced the evaporative cooling effect of the spray system, with the optimal concentration observed at 1.5%. The results demonstrate that enhancing the evaporative cooling efficacy of a spray system by introducing ethanol into the spray medium represents a viable strategy and improve urban thermal environment in summer. Furthermore, this study aims to examine the impact of droplet evaporation on relative humidity, establishing a foundation for future enhancements aimed at addressing the issue of over-humidification in spray systems.

Kinetics of chemical reactions in spray

The number of observations demonstrating a significant effect of droplet sizes on the kinetics of chemical processes has increased with the expansion of the scope of application of spray technology. The equations linking the concentrations of reagents, the volume of droplets, the initial composition of the solution, the composition of the gas medium and the speed of processes are formulated within the framework of formal chemical kinetics. Using the example of second-order reactions (coupling, exchange, condensation, polymerization, polycondensation), it is shown that size kinetic effects occur when chemical processes are accompanied by changes in the droplet sizes in equilibrium with the gas medium. The results of computer simulation of condensation reaction and polycondensation process reproducing size effects are presented. Kinetic curves obtained by modeling the polycondensation process are compared with experimental data.

The reduction of chemical inputs by ultra-precise smart spot sprayer technology maximizes crop potential by lowering phytotoxicity

Weeding is at the heart of agriculture. Today, using herbicides is unavoidable in conventional agriculture. However, increasing ecological awareness, the need to reduce carbon dioxide emissions, and the pursuit of sustainable food have driven industries and academics to explore new approaches for growing and protecting crops. In this context, smart spot sprayers emerge as a highly innovative alternative to broadcast treatments, which overuse pesticides, and mechanical weeding, which is limited by restrictive application conditions. Using artificial intelligence (AI) for plant recognition and ultra-precise spraying technology, herbicides are applied directly to weeds with minimal overspray, reducing their use by 90% compared to conventional methods. Spot sprayers' narrowly targeted spray limits chemicals' contact with the crop, resulting in low phytotoxicity, preserving natural crop development while maximizing yield potential. In addition, site-specific application increases the selectivity of chemical products artificially, enabling more concentrated mixtures to be used. Also, AI enables the selective application of non-selective molecules, supporting their use in established cultures. These characteristics open new opportunities for effective weed control where the traditional solutions fall short. This publication demonstrates the potential of the ultra-precise smart spot sprayer ARA in weed management in onion and sugar beet crops. Although comparing the overall performance of ARA with other smart spot sprayers on the market cannot be done in this article, this technology's potential in rendering weed management on farms more effective, sustainable, and saving labor without compromising yield is nevertheless indicated.

Microstructure and properties of Al/FeCoNiCrMo coatings prepared by different plasma spraying currents on carbon fiber reinforced plastic surfaces

Al/FeCoNiCrMo high-entropy alloy (HEA) coatings were prepared on the surface of carbon fiber reinforced plastic using plasma spraying technology. The microstructure of the HEA coatings was characterized under different spraying currents, and the hardness, interfacial bonding, corrosion resistance and friction and wear properties of the coatings were tested. The results showed that with the increase of the current, the unfused particles in the coatings decreased, and the coating porosity and thickness also decreased gradually; the hardness, corrosion resistance and friction and wear resistance properties increased with the increase of the current, in which the maximum hardness was 740.3 HV0.1, and the minimum self-corrosion current was 1.21 × 10−5 A·cm−2, and the minimum volumetric wear rate was 7.66 × 10−5 mm3·N−1·m−1.

Performance-tunable thermal barrier coating for carbon fiber-reinforced plastic composites via flame spraying

Thermal barrier coatings (TBCs) are essential for improving the heat resistance of materials operating in high-temperature environments. This paper proposes a new method for manufacturing double-layered TBC with graded porosity for carbon fiber-reinforced plastic (CFRP) composites. The TBC was created by a flame spraying process, consisting of relatively dense and porous layers: (1) a dense layer was produced by spraying yttria-stabilized zirconia (YSZ) particles directly onto neat carbon fabric substrate and (2) a porous layer was prepared by co-spraying YSZ particles with sacrificial polyetheretherketone (PEEK) particles. The porosity of the porous layer was controlled by varying a PEEK injection distance (D) and a PEEK feed rate (R). The correlation between porosity and thermal conductivity of the TBC layer was investigated to assess its thermal barrier performance. The TBC fabricated with the D = 5 cm and the R = 1.0 g/min offered the optimal porosity and conductivity. The 640μm-thick TBC with 34% porosity and 0.27 W/m·K thermal conductivity protected the CFRP substrate remarkably under the subjected torch at 500°C, as the TBC layer reduced the surface temperature of CFRP to 230°C. Thermomechanical analysis, following thermal shock tests, revealed that the double-layered TBC/CFRP composite retained 87% and 75% of its pristine flexural strength and modulus, respectively, while the neat CFRP composite was completely burnt out. This study explored the application of flame spray technology to develop highly effective double-layered TBCs with tunable porosity to maximize their thermal barrier performances. All results from the current study provide new insights into the design and development of TBC and CFRP composites, which will benefit a wide range of lightweight high-temperature applications.

Performance of Different Spray Nozzles in the Application of Defoliant on Cotton Plants (Gossypium hirsutum L.)

Defoliant spraying is an important link in the mechanized cotton harvest because adequate and uniform spraying can improve defoliation quality and reduce cotton trash content. In defoliant application, application volume and spraying technology are extremely important. In this study, the effectiveness of defoliant application to cotton plant that has come to harvest with two different application volumes and three different types of nozzles with a standard field crop sprayer was determined. Application rates were 250 and 400 L/ha and spraying nozzles were: (1) standard flat fan nozzle (TP8006), (2) air induction nozzle (AI 11002-VS) and (3) dual pattern nozzle (AI307003VP). A tracer (BSF) and defoliant were applied to mature cotton with approximately 60% open bolls and samplings for BSF deposition and spray coverage on cotton plant were done at two plant height (upper layer, lower layer) of plant. Before and after spraying, bolls open and leaves rate on cotton plants were calculated and filter papers were used to detect BSF deposition and water sensitive papers (WSP) were used to measure coverage rate of spraying methods used. Spectrofluorophotometer was used to detect the amount of tracer deposition on targets and an image process computer program was used to measure coverage rate on WSP. In analysis conclusions showed that air induction nozzle (AI 11002-VS), achieved better results than the dual pattern and standard flat fan nozzles in terms of higher depositions, coverages and leaf defoliations and boll opening rates. AI nozzles operating at 250 L/ha application rate provide the highest deposition and coverage rate on applications of defoliant, in addition, BSF as an indicator of the defoliant used reached on leaf beneath in merely this spray nozzle. After defoliation boll opining rate was 85-% on the 7th and 12th days after spraying and falling rate of leaves was 76-% at application rate of 250 L/ha with air induction (AI1102) nozzle.

Fostering rehydration and facilitating bioactive release through cellulose-assisted leaf surface treatment

Glyphosate is a widely used herbicide in weed control and crop protection. However, its low bioavailability on leaf surfaces of weeds led to excessive use of glyphosate, inducing herbicide-resistant development and major sustainable agricultural and environmental concerns. This study addresses these challenges by developing cellulose-assisted glyphosate formulations using superior rehydration and sustainable release capability of nanocelluloses. We prepared glyphosate-loaded nanocellulose particles (CNP) and cellulose nanofibers (CNF) to enhance the rehydration and sustained release of glyphosate on leaf surfaces. Our results have demonstrated that nanocelluloses significantly improved water capture on the leaf surface and gradual release of glyphosate, with CNP and CNF formulations showing an 8.75-fold increase in water adsorption on cotton leaves compared to the control group over 12 h. Furthermore, incorporating an inorganic salt improved moisture adsorption efficiency. The formulations exhibited high compatibility with existing spray technologies, offering substantial economic and environmental benefits for agriculture practices. This approach highlights the potential application of polysaccharides in revolutionizing agrochemical applications and environmental sustainability, providing great potential in agricultural spraying practices.