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<p>To meet the durability demands of Mg alloy under harsh chemical conditions, a water-repellent composite layer incorporating fluorinated SiO<sub>2</sub> nanostructures and polytetrafluoroethylene was applied via rod deposition. By systematically regulating the nanoparticle content, coating interfacial wetting behaviour and anti-corrosive performance were effectively modulated. At an optimal 5.0 wt% SiO<sub>2</sub> loading, the surface achieved a contact angle of 166° under a Cassie–Baxter air-layer regime, minimising solid–liquid interaction to 2.57%. Electrochemical tests revealed that the <i>I</i><sub>corr</sub> value of the superhydrophobic film-coated alloy decreased from 4.32 × 10<sup>–5</sup> to 2.04 × 10<sup>–9</sup> A&#xa0;cm<sup>−2</sup> relative to the uncoated substrate, while R<sub>ct</sub> increased from 293 to 287&#xa0;kΩ&#xa0;cm<sup>2</sup>. After immersion in an acidic environment (pH 3.5) for 7&#xa0;days, the coating maintained a low corrosion rate of ~ 2.51 × 10<sup>–5</sup>&#xa0;mm&#xa0;year<sup>−1</sup>, confirming its long-term protective stability. These results reveal the synergistic contributions of hierarchical nano-/microstructuring and air-cushion formation in suppressing electrolyte transport, providing a scalable pathway for developing corrosion-resistant polymer nanocomposites suitable for harsh service environments.</p>

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Mechanistic Insights into Superhydrophobic SiO2/PTFE Coatings Ensuring Durable Anti-Corrosion Performance on AZ31B Magnesium Alloy Under Acidic Conditions

  • 期刊论文

  • 发表日期：

    2026年3月18日

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  • Wenjuan Cui,
  • Leyan Tang,
  • Xiaoyu Zhou,
  • Xinxin Guo,
  • Zhuobin Huang,
  • Huangmeng He,
  • Xunfu Zhou,
  • Jin Luo,
  • Xiaomei Ning,
  • Guohua Zhou,
  • Chenyang Cai,
  • Xiaosong Zhou

摘要

To meet the durability demands of Mg alloy under harsh chemical conditions, a water-repellent composite layer incorporating fluorinated SiO2 nanostructures and polytetrafluoroethylene was applied via rod deposition. By systematically regulating the nanoparticle content, coating interfacial wetting behaviour and anti-corrosive performance were effectively modulated. At an optimal 5.0 wt% SiO2 loading, the surface achieved a contact angle of 166° under a Cassie–Baxter air-layer regime, minimising solid–liquid interaction to 2.57%. Electrochemical tests revealed that the Icorr value of the superhydrophobic film-coated alloy decreased from 4.32 × 10–5 to 2.04 × 10–9 A cm−2 relative to the uncoated substrate, while Rct increased from 293 to 287 kΩ cm2. After immersion in an acidic environment (pH 3.5) for 7 days, the coating maintained a low corrosion rate of ~ 2.51 × 10–5 mm year−1, confirming its long-term protective stability. These results reveal the synergistic contributions of hierarchical nano-/microstructuring and air-cushion formation in suppressing electrolyte transport, providing a scalable pathway for developing corrosion-resistant polymer nanocomposites suitable for harsh service environments.