Electrostatically sprayed superhydrophobic coating with integrated anti-icing, deicing, and robust mechanical durability

Ice formation on surfaces causes substantial economic losses and safety hazards, driving an urgent need for comprehensive anti-icing strategies that remain scientifically and technically challenging. In this work, a fluorine-free photothermal superhydrophobic coating was prepared on Q235 carbon steel via electrostatic powder spraying, integrating anti-icing, deicing, corrosion resistance and robust mechanical stability. The coating was constructed with modified SiC powder, modified SiC gel, and phenolic resin (PF) as the main photothermal components. The resulting material exhibited excellent superhydrophobicity, with the modified SiC gel enhancing interfacial interactions between the coating and the substrate, thereby improving mechanical durability and weather resistance. Electrochemical tests in 3.5 wt% NaCl solution confirmed its outstanding anti-corrosion performance. Under simulated sunlight exposure, the coating demonstrated highly efficient light absorption and photothermal conversion capabilities, achieving complete water droplet shedding in just 11 s, which indicates its outstanding anti-icing and de-icing performance under the combined active and passive effects. At −20 °C, the ice formation time on the treated surface was delayed by 6.5 times compared to the untreated surface. The prepared coating features high mechanical strength, environmental friendliness, and efficient anti-icing/de-icing properties, offering a promising strategy for long-lasting anti-icing protection in practical applications. • Application of electrostatic spraying technique for fabrication of superhydrophobic coatings. • The coating achieves synergistic active/passive de-icing capabilities. • Enhanced wear durability of the anti-icing coating through the incorporation of a reinforced SiC gel network.