Role of transfer film formation in wear resistance of self-similar superhydrophobic nanocomposite coatings

Nanocomposite coatings made from nanoparticles and organic adhesives are commonly used to create sprayable superhydrophobic (SH) coatings. However, their nano/microstructures are prone to damage under various wear conditions. This study explores the wear modes of self-similar SH coatings composed of SiC whiskers, silicone adhesives, and PTFE nanoparticles, including complex scenarios like wet sliding wear. In Taber tests, the coating showed only partial wear after 1000 dry cycles (CS-10/CS-17) and 900 wet cycles (CS-17) while maintaining stable superhydrophobicity throughout the entire test. Results show that transfer film formation causes microstructural failure, influenced by the organic compound ratio and wear conditions. Adding whiskers prevents transfer film formation by producing rough wear debris, offering a simple, eco-friendly, and effective method to improve the wear resistance of SH nanocomposite coatings.