Bristle worm inspired ultra-durable superhydrophobic coating with repairable microstructures and anti-corrosion/scaling properties

Superhydrophobic surfaces integrated with great water-repellency have been extensively studied while their practical applications are restrained by the infirm rough structures and poor chemical durability. In this study, an ultra-durable superhydrophobic polyphenylene sulfide (PPS) composite coating with repairable microstructures has been constructed by innovatively introducing the expandable graphite (EAG) and elastic fluororubber. Hydrophobic [email protected]2 nanoparticles synthesized by sol–gel and modified with perfluorodecyltrichlorosilane (PFTS) can expand to establish abundant micro/nanostructures for superhydrophobicity during the thermal treatment. Additionally, fluororubber powders as elastic micro-supports endows the surface structures with reversible deformation to resist the external mechanical damage. The prepared coating can restore its microstructures and superhydrophobicity even after 2000 abrasion cycles under a pressure of 125 kPa, exhibiting a fantastic mechanical durability. Moreover, the fabricated coating possessed good anti-corrosion and anti-scaling properties in high salinity oil/water emulsion due to the intrinsic oleophilicity of [email protected]2 and fluororubber, which can transform the surface shielding layer from fragile air film to stable oil film to impede scaling and corrosion mediums. Simultaneously, the prepared superhydrophobic coating also demonstrated outstanding self-cleaning and anti-fouling properties to prevent surface contamination by diatomite or glutinous slurry during outdoor application. Thus, this ultra-durable superhydrophobic coating with extraordinary repairable microstructures and anti-corrosion/scaling capabilities will be expected to open a new avenue to realize the large-scale applications of superhydrophobic coatings in harsh environments.