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Journal of Polymer & Composites Original Research Open Access

Development of a Durable Superhydrophobic EP/PDMS Coating Reinforced with Micro-CaCO₃ and Nano-ZnO for Enhanced Corrosion Protection and Multifunctional Performance on Carbon Steel

  1. Nurul Nabila Binti Mohd Din Engineering Materials and Structures (EMaSt), Malaysia-Japan International Institute of Technology (MJIIT), Universiti Teknologi Malaysia (UTM), Jalan Sultan Yahya Petra, Kuala Lumpur
  2. Norhasnidawani Binti Johari Department of Mechanical Precision Engineering (MPE), Malaysia-Japan International Institute of Technology (MJIIT), Universiti Teknologi Malaysia (UTM), Jalan Sultan Yahya Petra, Kuala Lumpur
  3. Mohd Aidy Faizal Bin Johari Engineering Materials and Structures (EMaSt), Malaysia-Japan International Institute of Technology (MJIIT), Universiti Teknologi Malaysia (UTM), Jalan Sultan Yahya Petra, Kuala Lumpur
  4. Noor Azlina Binti Hassan Department of Manufacturing and Materials Engineering, Faculty of Engineering, International Islamic University Malaysia (IIUM), Jalan Gombak, Kuala Lumpur
  5. Abd Halim Bin Md Ali Malaysia-Japan Advanced Research Centre (MJARC), Malaysia- Japan International Institute of Technology (MJIIT), Universiti Teknologi Malaysia (UTM), Jalan Sultan Yahya Petra, Kuala Lumpur
  6. Rizal Arifin Faculty of Engineering, Universitas Muhammadiyah Ponorogo, Jl. Budi Utomo No. 10 Ponorogo

Abstract

Balancing exceptional multifunctional performance with mechanical robustness in micro-nano composite films remains a significant challenge for practical applications. In this work, a superhydrophobic coating reinforced with micro-CaCO₃ and nano-ZnO particles was fabricated through a versatile single-step brushing method. The optimized EP/PDMS@micro-CaCO₃/nano-ZnO coating achieved a water contact angle (WCA) of 173.54° ± 2.53° and a sliding angle (SA) of 1.50° ± 1.12°. Owing to its carefully engineered micro-nano hierarchical structure, the coating exhibited outstanding friction coefficient reduction efficiency of 76.2% and mechanical durability Furthermore, the coating demonstrated superior anti-pollution properties, self-cleaning capability, substrate versatility, thermal stability, and anti-icing performance. Electrochemical evaluations revealed that the coating provided corrosion protection efficiency exceeding 99% in a 3.5 wt% NaCl solution, indicating substantially enhanced corrosion resistance. The results demonstrate that the modified CaCO₃ - ZnO nanoparticles do not merely function as surface roughness generators but actively reinforce the polymer matrix by enhancing interfacial bonding and suppressing nanoparticle pull-out during mechanical abrasion. The incorporation of PDMS further contributes to stress absorption while maintaining low surface energy, enabling sustained superhydrophobicity under repeated mechanical, chemical, and thermal exposure. This study provides new mechanistic insight into the durability of CaCO₃-based superhydrophobic coatings and shifts the focus of superhydrophobic coating design from short-term repellency performance toward durability-driven material engineering. The findings offer a viable strategy for developing robust superhydrophobic coatings suitable for marine atmospheric corrosion protection applications. The intrinsic properties of micro-CaCO₃/nano-ZnO particles, along with their highly ordered assembly within the coating, present a promising and effective strategy for the design and fabrication of multifunctional, all-in-one composite films.

Keywords

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