A comprehensive review on anticorrosive/antifouling superhydrophobic coatings: Fabrication, assessment, applications, challenges and future perspectives.

Superhydrophobicity (SHP) is an incredible phenomenon of extreme water repellency of surfaces ubiquitous in nature (E.g. lotus leaves, butterfly wings, taro leaves, mosquito eyes, water-strider legs, etc). Historically, surface exhibiting water contact angle (WCA) > 150° and contact angle hysteresis <10° is considered as SHP. The SHP surfaces garnered considerable attention in recent years due to their applications in anti-corrosion, anti-fouling, self-cleaning, oil-water separation, viscous drag reduction, anti-icing, etc. As corrosion and marine biofouling are global problems, there has been focused efforts in combating these issues using innovative environmentally friendly coatings designs taking cues from natural SHP surfaces. Over the last two decades, though significant progress has been made on the fabrication of various SHP surfaces, the practical adaptation of these surfaces for various applications is hampered, mainly because of the high cost, non-scalability, lack of simplicity, non-adaptability for a wide range of substrates, poor mechanical robustness and chemical inertness. Despite the extensive research, the exact mechanism of corrosion/anti-fouling of such coatings also remains elusive. The current focus of research in recent years has been on the development of facile, eco-friendly, cost-effective, mechanically robust chemically inert, and scalable methods to prepare durable SHP coating on a variety of surfaces. Although there are some general reviews on SHP surfaces, there is no comprehensive review focusing on SHP on metallic and alloy surfaces with corrosion-resistant and antifouling properties. This review is aimed at filling this gap. This review provides a pedagogical description with the necessary background, key concepts, genesis, classical models of superhydrophobicity, rational design of SHP, coatings characterization, testing approaches, mechanisms, and novel fabrication approaches currently being explored for anticorrosion and antifouling, both from a fundamental and practical perspective. The review also provides a summary of important experimental studies with key findings, and detailed descriptions of the evaluation of surface morphologies, chemical properties, mechanical, chemical, corrosion, and antifouling properties. The recent developments in the fabrication of SHP -Cr-Mo steel, Ti, and Al are presented, along with the latest understanding of the mechanism of anticorrosion and antifouling properties of the coating also discussed. In addition, different promising applications of SHP surfaces in diverse disciplines are discussed. The last part of the review highlights the challenges and future directions. The review is an ideal material for researchers practicing in the field of coatings and also serves as an excellent reference for freshers who intend to begin research on this topic.

Template-Free One-Step Electrodeposition Method for Fabrication of Robust Superhydrophobic Coating on Ferritic Steel with Self-Cleaning Ability and Superior Corrosion Resistance.

The corrosion of ferritic steel, a widely used structural material in the power and nuclear industries exposed to humid coastal environments, is a major concern. Here, we present a template-free one-step electrodeposition method for the fabrication of a robust superhydrophobic (SHP) coating on ferritic steel with excellent mechanical stability, enhanced corrosion resistance, and self-cleaning ability. By varying the electrodeposition time and potential, the micronanoscale hierarchical surface structures were optimized. The coated SHP surfaces were characterized by water contact angle measurement, Fourier transform infrared spectroscopy (FTIR), and scanning electron microscopy (SEM). The coated surfaces showed a characteristic cauliflower morphology of cerium myristate with micronanoscale features. The maximum water contact angle achieved was 162.8 ± 2.4°. Shear abrasion testing showed good mechanical durability for the prepared coatings. The as-prepared SHP coating showed a five order reduction in corrosion current density (4.14 × 10-11 A/cm2) and corrosion rate (4.63 × 10-7 mm/y) as compared to the bare sample. Further, a six order enhancement in the polarization resistance (1.55 × 109 Ω) was also observed in agressive chloride solution, which confirmed the excellent corrosion resistance of the SHP coating. Electrochemical impedance spectroscopy (EIS) studies showed a high impedance modulus for SHP coated surfaces due to the presence of a compact protective layer of cerium myristate. This observed impedance modulus of the SHP surface was approximately four orders higher than the reported value on magnesium alloys. This study provides a new platform for obtaining a robust, mechanically stable, and corrosion resistant SHP coating with a self-cleaning ability on ferritic steel substrates that may be adapted for a range of materials in practical applications.

Studies to control biofilm formation by coupling ultrasonication of natural waters and anodization of titanium.

The main objective of this study was to investigate the combined effect of ultrasonication of natural waters and anodization of titanium on microbial density and biofilm formation tendency on titanium surfaces. Application of 24 kHz, 400 W high power ultrasound through a 14 mm horn type SS (stainless steel) Sonicator with medium amplitude of 60% for 30 min brought about three order decrease in total bacterial density of laboratory tap water, cooling tower water and reservoir water and two order decrease in seawater. Studies on the effect of ultrasonication on dilute pure cultures of Gram-negative and Gram-positive bacteria showed five order and three order decrease for Pseudomonas sp. and Flavobacterium sp. respectively and two order and less than one order decrease for Bacillus sp. and Micrococcus sp. respectively. Ultrasonication increased lag phase and reduced logarithmic population increase and specific growth rate of Gram-negative bacteria whereas for Gram-positive bacteria specific growth rate increased. Studies on the biofilm formation tendency of these ultrasonicated mediums on titanium surface showed one order reduction under all conditions. Detailed biofilm imaging by advanced microscopic techniques like AFM, SEM and epifluorescence microscopy clearly visualized the lysed/damaged cells and membrane perforations due to ultrasonication. Combination of ultrasonication and anodization brought about maximum decrease in bacterial density and biofilm formation with greater than two order decrease in seawater, two order decrease in Bacillus sp. culture and more than four order decrease in Flavobacterium sp. culture establishing the synergistic effect of anodization and ultrasonication in this study.

Synthesis of one-dimensional ZnO nanostructures from Zn powder/granule.

We report the growth of one-dimensional ZnO nanostructures with different morphologies such as nanoneedles, nanorods, nanobelts from Zn powder/granule. The growth process is different from the conventional vapor-solid mechanism. The advantage of this method is that neither a catalyst nor any gas flow is required for the synthesis of nanostructures. Depending upon the Zn powder or Zn granules as the starting material different nanostructures have been synthesized which demonstrates the versatility of the technique.

Phenomenological predictions of cohesive energy and structural transition of nanoparticles.

In this paper, it is shown that a liquid-drop model (LDM) can predict the size-dependent cohesive energy (SDCE) of large nanoparticles and clusters (particles with few atoms) quantitatively. The cohesive energy decreases linearly with the inverse of the particle size both for large nanoparticles and clusters though the slopes are different. This indicates that there are three different regions (I-III) of SDCE in the complete size range. Regions I and II represent the SDCE of large nanoparticles and clusters, respectively, while region II represents the intermediate region where the cohesive energy is almost size-independent. Different regions of SDCE correspond to different structures of nanoparticles, and structural transition associated with the particle size can easily be predicted from the SDCE. Analyzing the cohesive energy data on the basis of LDM, it is shown that the surface tension decreases with decreasing size for very small nanoparticles. The Tolman equation can account for the variation of surface tension by predicting the size dependency of the Tolman length.