Optimizing processing parameters for fabricating Ni/SiO₂ coatings with enhanced superhydrophobicity and corrosion resistance via a one-step electrodeposition method

Building a superhydrophobic coating on a carbon steel substrate is an effective strategy for enhancing metal protection. A practical approach to producing a series of superhydrophobic Ni/SiO₂ composite coatings (SSN) using one-step electrodeposition method is shown. The effect of processing parameters on surface structure and wettability was thoroughly explored, resulting in the identification of three typical surface morphologies. The prepared coating with petal-like structure (SSN-3) obtained under the optimum parameters exhibited the best water repellency, achieving a contact angle of 162.7° and a sliding angle of 4.1°. The droplet bouncing behavior on SSN coatings surface was studied, and the delayed icing time was recorded. Meanwhile, the mechanical stability and chemical corrosion resistance of SSN coatings were focused. The superhydrophobic SSN-3 coating with unique surface structure exhibited excellent reliability. The anticorrosion mechanism of SSN-3 coating was discussed, and its corrosion protection efficiency was up to 98.5%. The superior properties of the superhydrophobic SSN-3 coating make it suitable for diverse applications.