Superhydrophobic Coatings for Corrosion Protection of Stainless Steel

Corrosion is a persistent challenge in the aviation industry, affecting the safety, performance, and maintenance costs of aircraft. While composite materials have gained widespread use due to their lightweight properties and corrosion resistance, certain critical parts, such as the wing and empennage leading edges and the engine inlet, demand alternative solutions. Aluminum, titanium, and stainless steel emerge as mandatory materials for such components, given their exceptional strength and durability. However, protecting these metallic components from corrosion remains crucial. In this paper, we present a study aimed at evaluating the corrosion resistance of stainless steel, employed as an erosion shielding panel for a composite vehicle's wing, layered with a superhydrophobic coating. The samples with and without coating have been characterized by contact angle measurements, microscopy (optical and electronic), and visual inspection after immersion in two solutions, NaCl and NaOH, respectively. The application of the superhydrophobic coating demonstrated a significant reduction in corrosion extent, especially in the demanding NaCl environment. This was evidenced by diminished formation of ripples and surface roughness, decreased iron oxide formation from oxidative processes, and a lower Surface Free Energy value in both liquid environments. Notably, the surface maintained its superhydrophobic properties even following an 8-day immersion in NaCl and NaOH solutions, demonstrating the reliability of the superhydrophobic coating offering as a potential solution to enhance the longevity and reliability of aircraft structures.