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<p>The development of superhydrophobic coatings resistant to combined mechanical–chemical stresses remains challenging. A solvent-free mechanochemical strategy is proposed to fabricate gradient-densified micro-nanohierarchical coatings on self-roughened copper foam. By synergizing sandpaper-induced microscale grooves with covalently anchored SiO<sub>2</sub> nanoclusters and recycled glass microsphere (GMs)-reinforced epoxy composites (where the GMs microscale particles were prepared by planetary ball milling via a top-down technique to acquire suitable roughness and size), a robust Cassie–Baxter state is stabilized, achieving a contact angle of 166° and sliding angle &lt; 5°. Electrochemical analysis in 3.5&#xa0;wt% NaCl reveals 98.82% protection efficiency. Finite element modeling confirms that GMs effectively delocalize strain, confining equivalent elastic strain below 0.001&#xa0;mm/mm over 90% of the surface area under 20&#xa0;N bending loads, while enabling pore gradient recovery. Superhydrophobicity is retained after a 5-m friction test, 100 blade-scratch cycles, and 180 cycles of 80&#xa0;°C boiling water immersion, driven by stress-adapted wettability where decreasing equivalent stress (71.25 to 11.76&#xa0;MPa) triggers contact angle recovery (143.75–153.36°) via microsphere-preserved re-entrant curvature. This work establishes a scalable paradigm for extreme-environment applications through covalent hybridization and microsphere-mediated strain engineering.</p> Graphical abstract <p></p>

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Mechanochemically fabricated superhydrophobic coatings with enhanced mechanical durability and corrosion resistance through microsphere-mediated strain engineering

  • 期刊论文

  • 发表日期：

    2026年7月18日

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  • Jie Su,
  • Yuqi Ouyang,
  • Sirui Li,
  • Lairong Yin,
  • Xinghe Jiang,
  • Bo Hu,
  • Haihang Wang

摘要

The development of superhydrophobic coatings resistant to combined mechanical–chemical stresses remains challenging. A solvent-free mechanochemical strategy is proposed to fabricate gradient-densified micro-nanohierarchical coatings on self-roughened copper foam. By synergizing sandpaper-induced microscale grooves with covalently anchored SiO2 nanoclusters and recycled glass microsphere (GMs)-reinforced epoxy composites (where the GMs microscale particles were prepared by planetary ball milling via a top-down technique to acquire suitable roughness and size), a robust Cassie–Baxter state is stabilized, achieving a contact angle of 166° and sliding angle < 5°. Electrochemical analysis in 3.5 wt% NaCl reveals 98.82% protection efficiency. Finite element modeling confirms that GMs effectively delocalize strain, confining equivalent elastic strain below 0.001 mm/mm over 90% of the surface area under 20 N bending loads, while enabling pore gradient recovery. Superhydrophobicity is retained after a 5-m friction test, 100 blade-scratch cycles, and 180 cycles of 80 °C boiling water immersion, driven by stress-adapted wettability where decreasing equivalent stress (71.25 to 11.76 MPa) triggers contact angle recovery (143.75–153.36°) via microsphere-preserved re-entrant curvature. This work establishes a scalable paradigm for extreme-environment applications through covalent hybridization and microsphere-mediated strain engineering.

Graphical abstract