Eco-friendly Superhydrophobic MWCNTs/PTFE/PEEK Powder Coating for Stable Superhydrophobicity in Extreme Environments

Superhydrophobic coatings hold broad application potential but face persistent challenges in thermal protection and mechanical robustness. Conventional fabrication methods further suffer from environmental and economic inefficiency associated with the use of organic solvents and complex equipment. Herein, a ternary nano/microintegrated composite of polyether–ether–ketone, polytetrafluoroethylene, and multiwalled carbon nanotubes was rationally designed and prepared via pressure-bonding technology. And thus, an eco-friendly superhydrophobic powder coating with exceptional thermal stability and long-term durability is successfully reported (WCA of 163.78°, WSA of 1.3°). This strategy addresses the inherent limitations associated with conventional melt-extrusion and direct-blending methods, such as thermal dispersion, homogenization, pulverization, and compatibility issues, thereby achieving a synergistic enhancement of material properties. The superhydrophobic coating demonstrates superior resistance to both cold and hot liquids. Also, it exhibits exceptional thermal stability (up to 400 °C) with simultaneous mechanical reinforcement, where the intertwined structure achieves high enhancement in abrasion resistance compared to direct-blended coatings. The chemically inert and rough surface also offers resistance to aggressive inorganic/organic solvents. Long-term environmental durability is evidenced by maintaining >150° WCA after 60 days of UV-accelerated aging. The coating’s stability under thermal, mechanical, and chemical stresses allows it to outperform conventional systems, offering a facile and innovative solution for surface thermal protection in extreme conditions.