Long-Term Static and Dynamic Corrosion Stability of Nonwetting Surfaces

Area of Science:

• Materials Science
• Surface Chemistry
• Corrosion Engineering

Background:

• Superhydrophobic surfaces (SHSs) and lubricant-infused surfaces (LISs) are advanced nonwetting surfaces with functional properties, including corrosion inhibition.
• A significant gap exists in understanding the corrosion behavior of SHSs and LISs concerning fabrication and material parameters, especially under challenging conditions like high temperatures, dynamic flow, and extended durations.

Purpose of the Study:

• To systematically investigate the corrosion inhibition performance of copper-based SHSs and LISs.
• To evaluate the impact of various fabrication methods (electrodeposition, etching) and material parameters (functionalization agents, lubricants) on corrosion resistance.
• To assess the long-term stability and durability of these nonwetting surfaces under static and dynamic corrosive environments, including high temperatures.

Main Methods:

• A full factorial combinatorial approach was employed to fabricate and test 90 copper surfaces.
• Two texturing processes (electrodeposition, etching), two functionalization agents (stearic acid, mercaptan), and two lubricants (Krytox 104, DOWSIL 510) were systematically varied.
• Over 650 measurements were conducted to assess water repellency (contact angle >150°, sliding angle <7°) and corrosion stability over 30 days in static and dynamic turbulent flow conditions.

Main Results:

• All fabricated surfaces exhibited excellent water repellency.
• LISs and SHSs demonstrated superior corrosion inhibition across all tested conditions, with minimal corrosion species observed.
• The nonwetting surfaces maintained their structural integrity and functional properties even after prolonged exposure to harsh environments.
• Surfaces showed facile rejuvenation of wettability and corrosion resistance properties.

Conclusions:

• Fabrication and material choices significantly influence the corrosion inhibition performance of SHSs and LISs.
• LISs and SHSs provide robust, long-term corrosion protection, even under demanding conditions like high temperatures and dynamic flow.
• These nonwetting surfaces are highly promising for applications requiring effective corrosion inhibition and can be easily restored to their original performance.
• The study offers valuable guidance for selecting optimal parameters for fabricating effective nonwetting surfaces for corrosion prevention.