A novel composite protective coating with UV and corrosion resistance: Load floating and self-cleaning performance

The research in functional materials has been the focus in studying industrial applications, particularly in the field of superhydrophobic functional bionic material. Although many studies of superhydrophobic surfaces have been published at this stage, the performance remain unsatisfactory, especially in a variety of harsh environments in practical applications, such as extremely cold weather, acidic or alkaline environment, prolonged exposure to light, high temperature, or oily wastewater, etc. The mechanical strength and corrosion resistance of coatings in such environments are all mighty challenges. In this study, we propose a fluoro silane-modified zinc oxide (FAS-ZnO) as a nano-filler. A superhydrophobic and oleophobic composite coating was successfully prepared through a single step by spraying suspensions containing attapulgite (ATP), FAS-ZnO, and carboxylated polyphenylene sulfide (PPS–COOH) onto desired substrates. In addition, stearic acid was added as a binder and used to enhance the bonding strength between the filler and the substrate. The composite coatings were characterized by FE-SEM, XRD and FT-IR on substrates, and the corrosion resistance of the coatings was evaluated by electrochemical impedance spectroscopy (EIS) and salt spray chamber experiments. The composite coatings showed excellent corrosion resistance due to the synergistic effect of FAS-ZnO and ATP. It was found that the composite coating had good hydrophobic and oleophobic contact angles of 161 ± 1.5° and 159 ± 1°, respectively, which were mainly attributed to the construction of nano-scale structures. It is worth noting that the composite coating performed excellently in chemical stability, self-cleaning performance, UV resistance, anti-fouling function, mechanical strength, and load-bearing floating ability. The coating maintained its highly hydrophobic surface after being stretched through a universal testing machine. Based on the multiple key properties in the composite coating, it can be expected to be applied to large equipment and instrument surfaces in extreme outdoor environments.