Fabrication of superhydrophobic surface by spraying hydrophobically modified silica nanoparticles on partially cured polyurethane paint

There is an increasing demand for superhydrophobic surfaces due to their unique properties like self-cleaning, anti-icing, corrosion resistance, etc. The development of polyurethane (PU)-based superhydrophobic coating has garnered significant attention for aircraft applications. Polyurethane (PU) topcoat is widely used in aircraft and is hydrophilic in nature with a water contact angle (WCA) of 75 ± 3°. In the present work, a hydrophilic PU clear coat on aircraft-grade aluminum substrate is transformed to a superhydrophobic (SHP) surface by spraying environmentally friendly hydrophobically modified silica nanoparticles (HSiNps) oonto a PU layer that was partially cured in a hot air oven at 60°C for 1.5 h. The SHP surface exhibited a WCA of 162 ± 3° and a sliding angle (SA) of 8 ± 3°. With the incorporation of HSiNps, micro – nano dual-scale surface roughness is created and the surface roughness of the PU coating is increased from 0.35 to 2.42 µm. The coating exhibits good adhesion (5B) with excellent water repelling property and remains thermally stable and superhydrophobic even after subjecting it to 100°C for one week. Durability of the coatings is studied by immersing the coatings in various liquids. The retention of superhydrophobic property after anti-fogging, water sprinkler, and sand paper abrasion tests further demonstrate the robustness of the coating.