Durable one-component polyurea icephobic coatings with energy-saving performance in electrical heating de-icing

Ice formation and accumulation on the surfaces of aircraft, wind turbines, and boat hulls might result in serious economic losses and catastrophic accidents. The development of a new generation of icephobic surfaces has emerged in recent years for anti-icing. However, insufficient durability of the existing icephobic surfaces remains a significant challenge to their applications. In this study, durable one-component polyurea icephobic coatings (OPICs) with a low ice adhesion strength (similar to 25.3 kPa) were prepared via a solvent-free method by combining the NCO-terminated prepolymer, latent curing agent, and silicone oil. The chemical structure, surface morphology, wettability, mechanical properties, icephobicity, and durability of the OPICs were studied. The optimized design of OPICs with synergistic icephobic mechanisms endowed them with excellent icephobicity and durability. The superior mechanical durability and chemical stability were revealed by the maintaining icephobicity of OPICs even after 3000 continuous Taber abrasion cycles, as well as 50 icing/de-icing cycles, 72 h of NaOH immersion, and 240 h of neutral salt spray test. The effect of OPICs on minimizing the electric power consumption was further investigated by icing wind tunnel. In comparison to the epoxy primer coated and Al alloy coated airfoil surface, airfoil surface coated by OPIC-30 was found to achieve about 43.7 % and 43.9 % energy savings in the keeping entire airfoil surface ice-free, respectively. The one-component polyurea icephobic coatings have great prospects for practical applications that require long-term anti-icing properties.