Mechanical-robust and polymer-based superhydrophobic coating toward self-cleaning and anti-corrosion

The corrosion of reinforced concrete materials severely threatens cross-sea bridges, buildings and marine ships. The unique air layer on the superhydrophobic coating surface can effectively minimize the reinforced concrete corrosion, which not only extends the long-term usability of concrete but also reduces economic losses and environmental pollution. It is necessary to design a superhydrophobic coating on substrate surfaces to accommodate the requirement for corrosion prevention due to their anti-corrosion and self-cleaning properties. Despite gradually developing superhydrophobic coatings to meet diverse needs, they still encounter limitations in engineering preparation and applications. For example, the rough micro-/nano structure of the superhydrophobic surface is easily damaged by mechanical impact or physicochemical damage, which could affect the antiseptic properties. Moreover, designing and preparing all polymer-based superhydrophobic micro-/nano structures using amorphous elastomer materials is vital for enduringly industrial applications, yet it remains a challenge. Here, we design and fabricate a mechanical-robust superhydrophobic coating composed of amorphous polyurethane (PU) and epoxy resin modified with amino-terminated polysiloxane (APT-PDMS) via a scalable atomization spraying method. A quartz sands impact abrasion test evaluates the mechanical durability of the PU superhydrophobic coating (PU-SC). The superficial PU particles can form elastic micro-protuberances, absorbing impact and preventing fracture through elastic deformation during friction. Furthermore, the as-prepared PU-SC can also resist some chemical mechanical damage, including acids/bases/salts solution corrosion, UV radiation, knife scraping treatment, 3M tape-stripping, water flow impact, outside sunlight shining treatment and temperature treatment. Notably, the robust PU-SC can be efficiently produced on a large scale and applied to prevent electrochemical corrosion in a simulated seawater environment. The corrosion protection efficiency (PE) can reach 98.1%. We believe that the design and development of a mechanical-robust and polymer-based super- hydrophobic coating has the prospect of actual application on marine corrosion.