Superhydrophobic shield: tetradecanoic acid-tailored eco-friendly zinc/zinc oxide coating on copper for enhancing anti-corrosion performance

Corrosion remains a major challenge, deteriorating metallic structures and causing substantial economic losses, accounting for nearly 4-5% of the global GDP annually.While conventional protective measures are widely used, they often introduce issues such as excessive material buildup, mechanical degradation, and environmental risks. These limitations drive the demand for advanced, eco-friendly solutions that ensure long-term durability without compromising structural integrity. Superhydrophobic coatings have recently gained attention due to their exceptional water-repellent properties, offering a promising solution. This study focuses on developing and characterising nanotextured myristic acid-modified Zn (Zn-MA) superhydrophobic coatings electrodeposited onto copper surfaces, optimised for enhanced hydrophobicity and corrosion resistance. By systematically varying electrodeposition parameters, such as voltage (6-10 V) and time, a uniform nanostructured zinc coating was achieved, increasing the water contact angle (WCA) from 73 degrees to 151 degrees. Subsequent modification with tetradecanoic acid (myristic acid) further increased the WCA to 163 degrees and reduced the surface coverage to 3.1%, demonstrating superior superhydrophobic properties. Electrochemical analysis revealed a peak corrosion resistance at 0.8 M tetradecanoic acid concentration, achieving 99.95% efficiency with a polarisation resistance of 99,230 Ohm-cm2 and a corrosion rate of 1.44 x 10(-16) mm/year. The coatings showed remarkable stability under extreme conditions, withstanding high pressures, prolonged exposure to chloride and sulphate environments, and elevated temperatures. Future work will focus on scaling fabrication, assessing durability in industrial settings, and integrating multifunctional protective layers.