Caspian Journal of Engineering Modern Technologies

Caspian Journal of Engineering Modern Technologies

Fabrication of Low-Cost Superhydrophobic Coating on Low-Carbon Steel Using Liquid Flame Spray

Document Type : Full Paper

Authors
Mechanical Engineering, University of Tehran, Tehran, Iran
Abstract
A nano-engineered superhydrophobic coating was fabricated using a two-step and low-cost method employing a liquid oxy-acetylene flame spray mechanism on mild A516 steel. Oxygen and acetylene were used as flammable gases. Nanostructured coating is obtained by flame spraying aluminum nitrate solved in ethanol on the substrate. To lower the surface energy, Perfluorodecyltriethoxysilane [PFDTES] and silicone elastomer were used. Results revealed that the wettability of the surface strongly depends on the precursor concentration so that at 3.5% concentration of aluminum nitrate in ethanol, maximum contact angle [157°] occurs. The distance between the substrate and nozzle is another key parameter to control and it directly affects the contact angle. Sandpaper abrasion test showed outstanding mechanical durability so that the coating maintained in hydrophobicity range under the load of 100 grams of weight and moving 10 cm on sandpaper 1000 grit for 8 cycles. The parameters affecting the process were thoroughly analyzed according to the applied liquid flame spray mechanism and the appropriate performance range of each was obtained that According to the experiments, the precursor flowrate and the distance between the substrate and nozzle should be repectively 0.9-1.9 ml/min and 14-22 cm.
Keywords
Subjects

  1. L. Pawlowski, The Science and Engineering of Thermal Spray Coatings, John Wiley & Sons, (2008).
  2. M. Aromaa, J. A. Pimenoff, J. M. Mäkelä, Liquid Flame Spray as a Means to Achieve Nanoscale Coatings with Easy‐to‐Clean Properties, Self‐Cleaning Materials and Surfaces: A Nanotechnology Approach, (2013) 229-251.
  3. J. M. Mäkelä, M. Aromaa, H. Teisala, M. Tuominen, M. Stepien, J. J. Saarinen, Nanoparticle deposition from liquid flame spray onto moving roll-to-roll paperboard material, Aerosol Science and Technology, 45(7) (2011) 827-37.
  4. J-P. Nikkanen, H. Keskinen, M. Aromaa, M. Järn, T. Kanerva, E. Levänen, Iron oxide doped alumina-zirconia nanoparticle synthesis by liquid flame spray from metal organic precursors, Research Letters in Nanotechnology, 2008 (2008).
  5. J. Pimenoff, A. Hovinen, M. Rajala, Nanostructured coatings by liquid flame spraying, Thin solid films, 517(10) (2009) 3057-3060.
  6. J. Yuan, Q. Zhan, Q. Lei, S. Ding, H. Li, Fabrication and characterization of hybrid micro/nano-structured hydrophilic titania coatings deposited by suspension flame spraying, Applied surface science, 258(17) (2012) 6672-6678.
  7. R. Jaworski, L. Pawlowski, F. Roudet, S. Kozerski, F. Petit, Characterization of mechanical properties of suspension plasma sprayed TiO2 coatings using scratch test, Surface and Coatings Technology, 202(12) (2008) 2644-2653.
  8. C. Lee, H. Choi, C. Lee, H. Kim, Photocatalytic properties of nano-structured TiO2 plasma sprayed coating, Surface and Coatings Technology, 173(2-3) (2003) 192-200.
  9. X. Chen, Y. Gong, X. Suo, J. Huang, Y. Liu, H. Li, Construction of mechanically durable superhydrophobic surfaces by thermal spray deposition and further surface modification, Applied Surface Science, 356 (2015) 639-644.
  10. F. Zhang, B. W. Robinson, H. de Villiers-Lovelock, R. J. Wood, S. C. Wang, Wettability of hierarchically-textured ceramic coatings produced by suspension HVOF spraying, Journal of Materials Chemistry A., 3(26) (2015) 13864-13873.
  11. P. Xu, T. W. Coyle, L. Pershin, J. Mostaghimi, Fabrication of micro-/nano-structured superhydrophobic ceramic coating with reversible wettability via a novel solution precursor vacuum plasma spray process, Materials & Design, 160 (2018) 974-984.
  12. H. Teisala, M. Tuominen, J. Haapanen, M. Aromaa, M. Stepien, J. M. Mäkelä, Switchable water absorption of paper via liquid flame spray nanoparticle coating, Cellulose, 21 (2014) 2033-2043.
  13. J. Haapanen, M. Aromaa, H. Teisala, M. Tuominen, M. Stepien, J. J. Saarinen, Binary TiO2/SiO2 nanoparticle coating for controlling the wetting properties of paperboard, Materials Chemistry and Physics, 149 (2015) 230-237.
  14. H. Teisala, M. Tuominen, M. Aromaa, J. M. Mäkelä, M. Stepien, J. Saarinen, Development of superhydrophobic coating on paperboard surface using the liquid flame spray, Surface and Coatings Technology, 205(2) (2010) 436-445.
  15. X. Chen, J. Yuan, J. Huang, K. Ren, Y. Liu, S. Lu, Large-scale fabrication of superhydrophobic polyurethane/nano-Al2O3 coatings by suspension flame spraying for anti-corrosion applications, Applied Surface Science, 311 (2014) 864-869.
  16. A. I. Y. Tok, F. Y. C. Boey, X. L. Zhao, Novel synthesis of Al2O3 nano-particles by flame spray pyrolysis, Journal of Materials Processing Technology, 178(1-3) (2006) 270-273.
  17. A. Ozturk, B. M. Cetegen, Experiments on ceramic formation from liquid precursor spray axially injected into an oxy-acetylene flame, Acta materialia, 53(19) (2005) 5203-5211.
  18. H. D. Jang, H. Chang, Y. Suh, K. Okuyama, Synthesis of SiO2 nanoparticles from sprayed droplets of tetraethylorthosilicate by the flame spray pyrolysis, Current Applied Physics, 6 (2006) e110-e113.
  19. M. Aromaa, H. Keskinen, J. M. Mäkelä, The effect of process parameters on the Liquid Flame Spray generated titania nanoparticles, Biomolecular engineering, 24(5) (2007) 543-548.
  20. C. Lv, H. Wang, Z. Liu, C. Wang, W. Zhang, M. Li, Y. Zhu, Fabrication of durable fluorine-free polyphenylene sulfide/silicone resin composite superhydrophobic coating enhanced by carbon nanotubes/graphene fillers, Progress in Organic Coatings, 134 (2019) 1-10.
  21. H. Wang, Z. Liu, E. Wang, X. Zhang, R. Yuan, S. Wu, Y. Zhu, Facile preparation of superamphiphobic epoxy resin/modified poly (vinylidene fluoride)/fluorinated ethylene propylene composite coating with corrosion/wear-resistance, Applied Surface Science, 357 (2015) 229-235.
  22. C. Wang, J. Xiao, J. Zeng, D. Jiang, Z. Yuan, A novel method to prepare a microflower-like superhydrophobic epoxy resin surface, Materials Chemistry and Physics, 135(1) (2012) 10-15.
  23. Y. Si, Z. Guo, W. Liu, A robust epoxy resins@ stearic acid-Mg (OH) 2 micronanosheet superhydrophobic omnipotent protective coating for real-life applications, ACS Applied Materials & Interfaces, 8(25) (2016) 16511-16520.
  24. X. Zhang, Y. Si, J. Mo, Z. Guo, Robust micro-nanoscale flowerlike ZnO/epoxy resin superhydrophobic coating with rapid healing ability, Chemical Engineering Journal, 313 (2017)1152-1159.
  25. H. Zhou, R. Chen, Q. Liu, J. Liu, J. Yu, C. Wang, Fabrication of ZnO/epoxy resin superhydrophobic coating on AZ31 magnesium alloy, Chemical Engineering Journal, 368 (2019) 261-272.
  26. X. Zhang, J. Liang, B. Liu, Z. Peng, Preparation of superhydrophobic zinc coating for corrosion protection, Colloids and Surfaces A: Physicochemical and Engineering Aspects, 454 (2014) 113-118.
  27. D. Lv, J. Ou, M. Xue, F. Wang, Stability and corrosion resistance of superhydrophobic surface on oxidized aluminum in NaCl aqueous solution, Applied Surface Science, 333 (2015) 163-169.
  28. Y. Liu, Y. Bai, J. Jin, L. Tian, Z. Han, L. Ren, Facile fabrication of biomimetic superhydrophobic surface with anti-frosting on stainless steel substrate, Applied Surface Science, 355 (2015) 1238-1244.
  29. X. Gao, Z. Guo, Mechanical stability, corrosion resistance of superhydrophobic steel and repairable durability of its slippery surface, Journal of colloid and interface science, 512 (2018) 239-248.
  30. J-F. Coulon, H. Maillard, Epoxy based composite surface analysis. A plasma treatment for wettability evolution, The European Physical Journal-Applied Physics, 49(1) (2010) 13111.
  31.  A. K. Bhowmick, J. Konar, S. Kole, S. Narayanan, Surface properties of EPDM, silicone rubber, and their blend during aging, Journal of applied polymer science, 57(5) (1995) 631-637.