Engineered superhydrophobic coating for anti-corrosion applications is a subject of great significance at present. However, the use of superhydrophobic coatings for anti-corrosion applications is hindered by the mechanical durability in many cases. There is a need for an understanding not only of how to fabricate such surfaces, but also of the corrosion resistance and mechanical durability of those coatings. This review discusses recent developments in the mechanical durability of superhydrophobic coatings primarily used for anti-corrosion. First, superhydrophobicity is introduced with an emphasis on different wetting models. After that, this review classifies the nanofabrication methods based on the material and methods of surface functionalization. Furthermore, the testing procedures used for the measurement of corrosion and mechanical durability are presented. Finally, the mechanical durability and anti-corrosion performance of the developed superhydrophobic coatings are discussed.

Artificial superhydrophobic copper surfaces play an important role in modern applications such as self-cleaning and dropwise condensation; however, corrosion resistance and durability often present as major concerns in such applications. In this study, the anti-corrosion properties and mechanical durability of superhydrophobic copper surface have been investigated. The superhydrophobic copper surfaces were achieved with wet chemical etching and an immersion method to reduce the complexity of the fabrication process. The surface structures and materials were characterized using scanning electron microscope (SEM), energy dispersive X-ray spectroscopy (EDX), and Fourier transform infrared spectrometer (FTIR). The corrosion resistance and mechanical properties of the superhydrophobic copper surface were characterized after immersing surfaces in a 3.5 wt % NaCl solution. The chemical stability of the superhydrophobic copper surface in the NaCl solution for a short period of time was also evaluated. An abrasion test and an ultrasound oscillation were conducted to confirm that the copper surface contained durable superhydrophobic properties. In addition, an atomic force microscope was employed to study the surface mechanical property in the corrosion conditions. The present study shows that the resulting superhydrophobic copper surface exhibit enhanced corrosion resistance and durability.

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Superhydrophobic coatings have shown tremendous improvement in the usability of metals such as aluminum. These coatings are capable of adding attractive features such as self-cleaning, anti-corrosion, and anti-biofouling to the array of diverse features that aluminum possesses, including lightweight and high ductility. For superhydrophobic surfaces, having considerable abrasion resistance is as important as achieving a high contact angle. In this work, two types of coatings have been prepared, each composed of functionalized silica nanoparticles along with polydimethylsiloxane (PDMS) dispersed in ethanol, and their superhydrophobicity and abrasion characteristics have been investigated. The same silica nanoparticles are present in each coating, but each has a different proportion of the PDMS base to its curing agent. The surface morphology of the coatings was studied with the aid of a scanning electron microscope (SEM) and an atomic force microscope (AFM). The surface chemical composition was characterized using an energy dispersive X-ray spectroscope (EDX). The prepared coatings were analyzed for their degree of superhydrophobicity, abrasion resistance and adhesion characteristics. In addition, atomic force microscopy was used to understand the adhesion characteristics of the coatings.

In this work, a mechanically durable anticorrosion superhydrophobic coating is developed using a nanocomposite coating solution composed of silica nanoparticles and epoxy resin. The nanocomposite coating developed was tested for its superhydrophobic behavior using goniometry; surface morphology using scanning electron microscopy and atomic force microscopy; elemental composition using energy dispersive X-ray spectroscopy; corrosion resistance using atomic force microscopy; and potentiodynamic polarization measurements. The nanocomposite coating possesses hierarchical micro/nanostructures, according to the scanning electron microscopy images, and the presence of such structures was further confirmed by the atomic force microscopy images. The developed nanocomposite coating was found to be highly superhydrophobic as well as corrosion resistant, according to the results from static contact angle measurement and potentiodynamic polarization measurement, respectively. The abrasion resistance and mechanical durability of the nanocomposite coating were studied by abrasion tests, and the mechanical properties such as reduced modulus and Berkovich hardness were evaluated with the aid of nanoindentation tests.