Electroless deposited NiP-PTFE composite coatings for anti-scaling application

Scale formation on metallic components represents a major issue in several industrial sectors, leading to efficiency losses, increased maintenance costs and premature equipment failure. In this work, electroless-deposited NiP–PTFE composite coatings were developed and investigated as anti-scaling surfaces. The coatings were synthesized by incorporating submicrometric polytetrafluoroethylene (PTFE) particles (average diameter ∼200 nm) into a NiP matrix through an autocatalytic plating process, aiming to combine the corrosion resistance of NiP with the low surface energy of PTFE. The influence of PTFE incorporation on coating morphology, composition and wettability was systematically analyzed. The submicrometric size of the PTFE particles enabled a relatively uniform distribution throughout the NiP matrix, minimizing aggregation phenomena and contributing to controlled modifications of surface topography. As a result, the composite coatings exhibited a marked increase in hydrophobicity compared to plain NiP coatings. Surface free energy analysis confirmed the significant role of PTFE in reducing the surface energy. Anti-scaling performance was evaluated through controlled calcium sulfate deposition tests, revealing a substantial reduction in scale adhesion on NiP–PTFE coatings relative to unfilled NiP surfaces. The improved anti-scaling behavior was attributed to the combined effect of reduced surface energy induced by the incorporation of ∼200 nm PTFE particles. These results demonstrated that electroless NiP–PTFE composite coatings represent a promising and scalable strategy for mitigating scale formation in industrial environments.