Advanced durable ceramic-polymer ultra-superhydrophobic coating with anti-icing, anti-vapor condensation, and corrosion-resistant properties

We present a mechanically robust, cost-effective, and scalable ultra-superhydrophobic ceramic-polymer composite coating featuring a hierarchical micro/nano-structured surface. This advanced coating, fabricated via a single-step process, integrates alumina (Al2O3) and zirconia (ZrO2) to harness their individual and synergistic effects, achieving an extreme water contact angle of 180° and a sliding angle of 1°. The coating demonstrates strong adhesion and compatibility with a wide range of substrates, including aluminum and concrete. The Al2O3–ZrO2-based composite exhibits outstanding physicochemical properties, including ultra-superhydrophobicity, anti-icing, anti-corrosion, and anti-vapor condensation capabilities. It also maintains excellent non-wetting behavior across a variety of liquids. Comprehensive surface analyses, encompassing microstructural, morphological, and chemical characterization, underscore the critical role of hierarchical structuring and tailored surface chemistry in enhancing functionality. Mechanical durability assessments reveal that the coating retains its superhydrophobic performance even after extensive scratching test. Moreover, it exhibits self-cleaning, anti-adhesion, and anti-fouling characteristics, attributed to its engineered surface texture and the synergistic contributions of Al2O3–ZrO2 heterojunctions and oxide-silane bonding (Si–O–Si and Si–OH). This multifunctional ceramic-polymer coating addresses key challenges in large-scale deployment by offering a streamlined, scalable fabrication method and versatile performance, positioning it as a promising solution for diverse industrial applications.