Development and characterization of rGO/PTFE hybrid bilayer coatings for efficient anti-icing and electro-thermal applications

Abstract This study investigates the electro-thermal de-icing, anti-icing, superhydrophobic, and mechanical properties of reduced graphene oxide (rGO)/polytetrafluoroethylene (PTFE) hybrid bi-layer coatings designed for cold weather applications. The bilayer design consists of a bottom rGO—epoxy conductive layer and a top rGO–PTFE hydrophobic layer, designed to provide multifunctional surface protection on CFRC substrate. The coating exhibits exceptional electrical conductivity and improved thermal conductivity, enabling fast Joule heating at both ambient and sub-zero temperatures. Upon the application of electricity, the surface temperature escalates rapidly, facilitating effective de-icing within seconds. The superhydrophobic top layer exhibits a water contact angle exceeding 152° and a significantly longer ice delay time, thereby markedly reducing ice accumulation. The coating exhibits little ice adhesion strength (<50 kPa), facilitating easy ice removal during the ice adhesion test. Nanoindentation studies demonstrate exceptional mechanical strength, with a nano-hardness of around 55 MPa, and an elastic modulus of around 1.4 GPa. The combined properties of rGO’s strong electrical and thermal conductivity, along with PTFE’s low surface energy, make the rGO/PTFE bi-layer coating an effective, resilient, and self-heating surface suitable for anti-icing and de-icing applications in the aerospace, energy, and transportation sectors.