Thermally stable, robust, superhydrophobic coating based on hydrophobic/hydrophilic dual-size particles

Superhydrophobic coatings have garnered significant attention in the aerospace industry due to their unique functionalities. However, most reported coatings are restricted by poor thermal stability (typically below 400 °C), complex fabrication processes, or reliance on fluorinated raw materials, which limit their practical applications. This study employs a fluorine-free water-based acrylic/organosilicon composite resin and dual-scale SiO2/ZrO2 particles to prepare a high-temperature-resistant superhydrophobic coating. The coating exhibits a water contact angle (WCA) of 156.1° and a sliding angle (SA) of 6.9°. Additionally, it maintains good hydrophobicity even after being treated at 500 °C for 1 h. In addition, the coating demonstrates excellent multifunctional durability, including resistance to 200 abrasion cycles, electrolyte corrosion, acid–base solutions, and common organic solvents. Benefiting from its environmentally friendly composition and simple spray-coating process, this work provides a scalable strategy for fabricating robust superhydrophobic coatings tailored for demanding aerospace environments.