Efficient one-step fabrication of ceramic superhydrophobic coatings by solution precursor plasma spray

Abstract Superhydrophobic ceramic coatings with high water contact angle and excellent water repellency were fabricated by a one-step solution precursor plasma spray process without using any low-surface-energy polymeric modifiers. The coating composition and microstructure were characterized, and showed a two-length scale micron/nano-sized hierarchical structure. The hydrophobicity of the coatings was tested via water contact angle measurement, water roll-off angle and droplet impact tests. The water contact angle of the coatings reached 163° and the water roll-off angle was about 6.5°. The microstructure and hydrophobicity of the coatings could be varied by tailoring the parameters of the spraying process. The results indicate that solution precursor plasma spray is an efficient method by which to fabricate various hydrophobic ceramic coatings in large scale.