Synthesis of high-temperature hydrophobic nanoparticles and their applications in superlyophobic coatings

The development of superhydrophobic coatings for high-temperature applications remains fundamentally constrained by the thermal degradation of organic constituents. This work presents a novel flame-assisted pyrolysis synthesis of high-temperature-stable hydrophobic nanoparticles (HTHP-NPs) from a TiO₂-reinforced polydimethylsiloxane microsphere (MS)/silicone adhesive (Ad)/carbon fiber (C_f) composite system. The resulting HTHP-NPs-covered MS/TiO₂/Ad/C_f composite coatings exhibit remarkable thermal resilience, preserving superhydrophobicity (CA = 169.7 ± 1.1°; SA = 2.4 ± 0.7°) during sustained 400–500 °C furnace exposure (100 h) and transient 850 °C flame tests (>20 s). These coatings display exceptional repellency toward various high-temperature liquids, including molten salt, sodium acetate, glass, and solder. The enhanced high-temperature oxidation resistance stems from the kinetic suppression of precursor oxidation by the composite microstructure and the oxygen scavenging effect of C_f decomposition at high temperatures. Additionally, the HTHP-NPs assemblies demonstrate remarkable mechanical resilience, preserving nanoscale roughness even after severe mechanical damage (1500 Taber abrasion cycles, impact energy density of 3.12 × 10⁶ J m⁻²). These advancements bridge the gap between superlyophobicity and high-temperature durability, enabling robust performance in extreme thermal environments.