Critical insights into anti-icing mechanisms of superhydrophobic coatings & impact of surface features and material engineering: a comprehensive review

Abstract Ice formation on bare surfaces poses a serious problem in aerospace, wind power, power transportation, and transportation. Superhydrophobic coatings (SHCs) are a new potential passive anti-icing application owing to their remarkable water repellency, which has a high contact angle and low hysteresis. This comprehensive review investigates the use of surface roughness, contact angle dynamics, and material selection in regulating the anti-icing efficiency of SHCs. The relationship between droplet behavior and surface morphology was investigated in terms of the Cassie-Baxter and Wenzel wetting conditions and their effects on ice nucleation and adhesion. The composition of materials such as fluorinated polymers, metal oxides, and hybrid nanocomposites is considered in terms of their contribution to the durability of the surface used and reduced surface energy. In addition, recent developments in fabrication processes, including electrodeposition, electrospinning, and sol–gel, are discussed within the context of scalability, mechanical strength, and environmental friendliness. Problems with mechanical wear, damage from sunlight, and staying stable in tough conditions are discussed. Recent advances in self-repairing and temperature-sensitive coatings are also discussed. The adoption of hybridization of superhydrophobicity with photothermal and electrothermal capabilities is emphasized as a way forward to develop durable and energy-efficient anti-icing capabilities. This review offers information about structure–property-performance relationships to help design next-generation coatings with the capability to perform anti-icing reliably in a multidisciplinary engineering performance.