Superhydrophobic Coatings Based on PMMA-Siloxane-Silica and Modified Silica Nanoparticles Deposited on AA2024-T3

The study aimed to develop a superhydrophobic coating on the aluminium alloy 2024-T3 surface. The desired surface roughness and low surface energy were achieved with SiO2 nanoparticles, synthesised via the Stöber method and modified with alkyl silane (AS) or perfluoroalkyl silane (FAS). To enhance particle adhesion to the alloy substrate, nanoparticles were incorporated into a hybrid sol–gel coating composed of tetraethyl orthosilicate, methyl methacrylate, and 3-methacryloxypropyl trimethoxysilane. The coated substrates were characterised using field emission scanning and transmission electron microscopy with energy-dispersive spectroscopy for surface topography, nanoparticle size distribution, composition, and coating thickness. The corrosion resistance of the coatings on AA2024-T3 was evaluated in a 0.1 M NaCl solution using electrochemical impedance spectroscopy. The synthesised SiO2 nanoparticles had an average size between 25 and 35 nm. The water contact angles on coated aluminium surfaces reached 135° for SiO2 + AS and 151° for SiO2 + FAS. SiO2 + FAS, indicating superhydrophobic properties, showed the most uniform surface with the most consistent size distribution of the SiO2 nanoparticles. Incorporation of nanoparticles into the hybrid sol–gel coating further improved particle adhesion. The ~2 µm-thick coating also demonstrated efficient barrier properties, significantly enhancing corrosion resistance for over two months under the test conditions.