Advanced superhydrophobic and wear-resistant coatings on carbon steel

Purpose This study aims to develop a dual-action coating combining superhydrophobicity and wear-resistance on carbon steel. Design/methodology/approach Superhydrophobic coatings were fabricated by blending perfluorodecyltrimethoxysilane (FAS)-modified nanoparticles (SiO2, TiO2, ZrO2) with silane coupling agent-modified epoxy resin (Ep-51). Key parameters – epoxy content, nanoparticle type and silane agent (KH-540, KH-550, KH-560) – were optimized. Coatings were characterized via scanning electron microscopy, atomic force microscopy, FT-IR, contact angle measurements, pencil hardness tests and abrasion resistance evaluations. Findings The optimal coating (FAS-SiO2:KH-560-modified Ep-51 = 10:4) exhibited outstanding superhydrophobicity (153°), high hardness (6H) and superior abrasion resistance. Increased Ep-51 content enhanced hardness but reduced hydrophobicity due to nanoparticle encapsulation. SiO2 outperformed TiO2/ZrO2 in hydrophobicity, while KH-560 provided optimal mechanical–hydrophobic balance. The coating maintained functionality after abrasion. Originality/value This work presents a novel sprayable nanocomposite coating integrating superhydrophobicity and robust mechanical durability. The dual-layer design offers a scalable solution for long-term protection in industrial applications.