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A super hydrophobic coating is a surface treatment that significantly reduces water adhesion, resulting in water droplets beading up and rolling off instead of spreading out and wetting the surface. This is achieved by micro- and nanostructures on the surface, which lower the surface energy. Such coatings have become increasingly useful in many industrial settings.
The following are some types of coatings that can benefit from such waterrepellant coatings:
Heat resistant coating
Heat resistant coatings are usually applied in areas with high temperatures and hence protect the substrate from thermal degradation. This can be applied in areas such as automotive parts that may be exposed to exhaust heat or furnaces, crucibles, and kilns.
Industrial anti-corrosion coatings
These anti corrosion coatings are commonly used in the industrial sector. They are applied to machines, tools, and other equipment. This helps with the longevity of the equipment and reduces maintenance costs and downtime.
Vapor deposition coatings
This refers to a set of processes used to produce thin films on substrates. Hydrophobic coatings help improve the durability of such fragile coatings. The hydrophobic coating can be applied during the fabrication of semiconductor components or optical coatings.
Black oxide coatings
The black oxide coating is usually used in ferrous and non-ferrous metals as well as steel alloys, particularly in aerospace, military, and other industries that require high performance. In that regard, superhydrophobic coatings can be used to boost the black oxide coating's corrosion resistance and minimize wear.
Ceramic coatings
Ceramic coatings are usually applied in conditions of extreme heat, corrosion, and mechanical wear. They are used in automotive parts such as engine components, turbo chargers, and exhaust systems, as well as aerospace components. Superhydrophobic coatings can be used to enhance the already great corrosion and wear resistance of ceramic coatings in the harsh environments mentioned above.
Electroplating
Electroplating is a coating technique that uses an electric current to deposit metal ions onto a surface. Commonly coated metals include zinc, nickel, chrome, copper, gold, and silver. Superhydrophobic coatings help further prevent corrosion and oxidation while also extending the lifespan of the electroplated surface.
Powder coatings
Powder coatings provide a protective layer that is more durable than liquid coatings. It can be applied to automotive parts, industrial machinery, and other steel or iron components. An additional superhydrophobic layer can enhance the protective capabilities of powder coatings by making it more resistant to water and other environmental elements.
The superhydrophobic coating can be used in the following industrial applications:
Oil and gas
In this field, hydrophobic coatings can be used on offshore oil rigs, pipelines, and exploration equipment to reduce the risk of corrosion and ice formation. This helps in making equipment fairly immune to water-related damage and helps with maintenance reduction and increased lifespan.
Marine Industry
In this field, vessels and equipment are exposed to water constantly, which causes corrosion. Hydrophobic coatings can be applied to ship hulls, propellers, and underwater components to reduce marine growth, barnacles, and corrosion. Coating water- and corrosive-element-sensitive parts prolongs their lifespan and reduces maintenance and repair costs.
Aerospace
Aerospace components and materials are exposed to extreme conditions, including high-altitude humidity. Anti hydrophilicity coatings can protect critical parts like sensors, avionics, and turbine blades from water accumulation, ice formation, and associated structural degradation.
Construction
In this industry, the coatings can be applied to surfaces like concrete, steel, and glass in buildings. The coatings prevent water ingress, façade deterioration, and mold growth. Hydrophobic coatings can also be applied to building materials before installation to reduce water-related damage and improve durability.
Textiles
Hydrophobic coatings are increasingly being applied to fabrics in this industry to offer water and stain resistance without affecting breathability. The coatings are applied in the fashion industry to make garments waterproof, in the automotive industry for seat covers, and in home textiles like curtains for water resistance and easy cleaning.
Automotive
Car parts and surfaces in the automotive industry undergo frequent exposure to water, rain, and humidity. Hydrophobic coatings can be applied to windshields, bodywork, metal parts, and undercarriages to prevent water spots, corrosion, and rust. It also helps with reduced vehicle maintenance and increased long-term performance.
Manufacturing
Superhydrophobic coatings can help reduce water-related defects in this industry. Applying them to machinery, molds, and products like electronic components, tools, and equipment ensures reduced water contact. This leads to increased product quality and fewer defects, as well as extended equipment life and reduced maintenance due to minimized water accumulation and corrosion.
The method of application for superhydrophobic coating is determined by the type of coating and the nature of the surface to be coated. The following are the general ways to apply:
Chemical vapour deposition (CVD)
The surface to be coated is first prepared by cleaning it. The CVD process entails the deposition of coating material from a gaseous state onto the surface. This method is applied mainly when the coatings are to be applied on semiconductor components, optical devices, or any other item where high temperatures and chemical exposure are contraindicated.
Electroplating
During electroplating, an electric current is passed through a solution containing metal ions. This will cause the metal to be deposited onto the surface of the object. Before the plating takes place, the surface is usually cleaned and pre-treated. Once the coating has been applied, a post-treatment is conducted, where superhydrophobic chemicals are sprayed or immersed onto the electroplated item to enhance its anticorrosive properties.
Thermal spraying
In this method, the coating material is heated and then sprayed onto the surface to form a coating layer. Before applying the coating, the surface is usually cleaned and prepared. This method is commonly used on industrial machinery and components in environments subject to extreme conditions.
Sol-gel process
The sol-gel method prepares a liquid solution that will be transformed into a solid coating and deposits it onto the surface. Before deposition, the surface is cleaned. The technique enables the formation of thin, uniform coatings that can be applied to various substrates, including glass, metals, and ceramics. This is especially useful where transparency and a low coating weight are required.
Nanoparticle spraying
A suspension containing nanoparticles is prepared and sprayed onto the surface to create a superhydrophobic layer. The surface is cleaned, and the nanoparticles are usually silica or polymeric in nature. They are then contained within the spray solution. After applying the nanoparticles, the surface is treated thermally or chemically to ensure the nanoparticles bond to the surface.
Inventory coating
For larger industrial applications, a hydrophobic formula is usually applied using a spray, brush, or roller over portions of structures. In this method, it is mainly used for large equipment, machinery housing, and structural components.
Here's how to maintain super hydrophobic surfaces:
Coating quality standards
Make sure the coating is at least ISO certified. The ISO 2577 primarily deals with coatings and paints and samples preparation while the ISO/IEC 17025 deals with general requirements for the competence of test and calibration laboratories.
Material safety
As mentioned, superhydrophobic coatings are manufactured using nanoparticles, mostly silica or polymers. Ensure that the silica used is from a reputable source and is pure and with no contaminants. When applying the coating, ensure all personnel are equipped with PPE so as not to inhale the silica dust. It is recommended that silica exposure in air should have an ambient silica concentration of less than 0.1 milligram, which is about 0.8% of a typical workplace's silica.
Surface preparation
Surface pre-treatment is usually a critical stage in the coating process because it directly affects the coating's adhesion and performance. However, take care to ensure that the cleaning agents used are safe for the environment and workers.
Application method
As discussed before, superhydrophobic coatings can be applied through chemical vapour deposition, electroplating, sol-gel, thermal spraying, and spraying. Ensure that the application method is done in an environment with proper ventilation.
Curing process
Some hydrophobic coatings have a curing stage, usually a thermal curing stage. It is critical to ensure that there are no accidental emissions and that protective measures are undertaken where open flames are involved. Ensure that there are no flammable substances within the vicinity.
Product performance
When purchasing superhydrophobic coatings, only purchase those that have been tested for temperature and mechanical wear. Such coatings have increased chances of not being hazardous during exposure to heat or friction. Also, ensure that the coating materials used have undergone quality tests for purity and quality control. This reduces the risk of pollutant generation.
Waste management
Ensure that all wastes from the coating process, such as used silica nanoparticles, spent superhydrophobic coating materials, cleaning rags, PPE, or any other waste, are disposed of properly in accordance with local regulations.
A1:Industries like oil and gas, construction, marine, aerospace, automotive, manufacturing, and in x-ray coating for semiconductors and other optical devices apply superhydrophobic coatings to equipment, parts, and materials to protect them from corrosion and other water-related damage, reduce maintenance needs, and extend the life of critical components.
A2: Key benefits include protection from corrosion and water damage, extended equipment and material lifespan, reduced maintenance needs, and improved product quality in industries prone to water exposure or environmental wear.
A3: Superhydrophobic coatings are made from silica nanoparticles, fluorinated polymers, or other low surface energy materials. These form a micro- and nanostrotsurface that greatly reduces water adhesion.
A4: The degree of hydrophobicity is measured using the contact angle formed between a water droplet and the surface. The higher the angle, the more hydrophobic the surface is.
A5: While many superhydrophobic materials are environmentally safe, some nanoscale materials may have potential environmental health risks. Therefore, proper precautions should be taken when handling them, such as using PPE and proper ventilation.
