Preparation of superhydrophobic coating with excellent abrasion resistance and anti-icing properties using Al2O3/PVDF composites with different Al2O3 particle sizes

doi:10.21203/rs.3.rs-2619127/v1

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Preparation of superhydrophobic coating with excellent abrasion resistance and anti-icing properties using Al2O3/PVDF composites with different Al2O3 particle sizes

https://doi.org/10.21203/rs.3.rs-2619127/v1

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Considering the application areas of ceramic materials (ceramic sinks, toilet bowls, washing areas, ceramic tiles tableware), the demand for improving dirt and water repellent properties is increasing day by day with the perception of hygiene and cleanliness that affects the whole world. In this study, super-hydrophobic solutions were prepared and applied to ceramic substrates by adding alumina particles with different particle size distributions into the polyvinylidene fluoride (PVDF) matrix. Alumina powders added to the PVDF matrix at four different rates to obtain composite materails. Alumina powders with two different particle sizes, coarse and fine, was used and the effect of grain size on the properties was investigated. The adhesion performance of the coatings was determined by brush tests. In addition, surface roughness values, colour variation after coating, and anti-icing performance were also evaluated. It was observed that the coating with the (PVDF:Al₂O₃) ratio (1:0.25) had the highest contact angle and adhesion property.

PVDF

alumina

composite

superhydrophobic coatings

contact angle

In recent years, some applications of superhydrophobic coatings, such as self-cleaning, anti-icing and anti-corrosion properties, have attracted great interest due to wide applications in science and engineering [1, 2]. Such water-repellent coatings with static contact angle greater than 150° and low slip angle are highly desirable for anti-corrosion, anti-icing, self-cleaning and anti-slip applications [3–5]. Fluoropolymers are often prefered for the superhydrophobic effect [6, 7]. Fluoropolymers are known to have excellent chemical resistance to acids, bases, and solvents and good high-temperature stability, release, and non-stick properties. The polyvinylidene fluoride (PVDF) is also one of the fluoropolymers used for the hydrophobic effect [8]. PVDF stands out with outstanding wear resistance, corrosion resistance, and thermal stability properties. It is a high-performance coating material with semi-crystalline properties widely used in applications requiring excellent physical, chemical, and mechanical properties, including outdoor applications [9]. Various solid particles can be added to provide surface roughness to increase hydrophobicity [10]. Solid particles can be elements such as nickel, graphene, cerium, salts such as ammonium carbonate, and metal oxides such as TiO₂, SiO₂, and Al₂O₃. Basu and Kumar [11] studied creating a superhydrophobic surface by incorporating silica nanoparticles into a PVDF matrix. As a result, 10wt. % PVDF coatings with a PVDF:SiO₂-1:1 ratio loading weight show the best superhydrophobic and mechanical properties. It also has the lowest dirt build-up and the highest self-cleaning efficiency. Wu et al. [12] prepared mechanically robust superhydrophobic coatings by sol-gel method, with 10–20 nm sizes of SiO₂ nanoparticles added as reinforcement. In addition, PVDF-based composites can be applied on many substrates. Yun Hwan Kim et al. [13] studied the effect of mixing ratio on corrosion protection of carbon steel coated with a film containing PVDF and poly-methyl methacrylate (PMMA) using electrochemical impedance spectroscopy. Anand Ganesh et al. [14] applied the nano composite coating containing PVDF to glass surfaces by electrospinning method. Shi et al. applied SiO₂ doped PVDF-based composite to the paper surfaces and interpreted their results. Wang et al. [15] prepared a superhydrophobic coating by electrospinning method. They used PVDF mixed with epoxy-siloxane modified SiO₂ nanoparticles. Basu and Paranthaman [16] obtained a superhydrophobic surface by using hydrophobically modified fumed silica (HMFS) particles in PVDF matrix.

In this study, unlike its counterparts in the literature, alumina particles were added to the PVDF matrix to increase the degree of hydrophobicity and applied on ceramic surfaces. In particular, the effect of particle size on hydrophobicity was investigated using alumina in two different particle size distribution ranges. In addition, effects such as adhesion performance, contact angles, anti-icing properties, and changes in coating color of the studied composites were also examined. It was determined that the contact angles and adhesion performances of the Al₂O₃/PVDF composites with fine particle size distribution were relatively high, and no color change was observed in the sample.

2.1. Materials and coating solution preparation

The coating system consists of PVDF as the matrix, N-N dimethylformamide (DMF) and tetrahidrofuran (THF) as the solvent. Surface roughness was introduced by the addition of two different alumina particles. The particle size distributions of the two different alumina used are given in Table 1. The average particle size of the A1 sample is 69.60 ± 0.5 µm, while the average particle size of the A2 sample is 3.97 ± 0.5 µm. Distilled water and ethanol were used as solvents during the preparation. (All the chemicals were supplied by Sigma Aldrich.)

Table 1

Two different alumina particles and their particle size distribution
Sample Code	d10(µm)	d50(µm)	d90(µm)
A1	19.74 ± 0.5	67.19 ± 0.5	126.45 ± 0.5
A2	1.28 ± 0.5	2.87 ± 0.5	6.02 ± 0.5

PVDF was first prepared without additives. THF and DMF added ratio of (1:1) by weight and mixed. PVDF was added at a rate of 5.0% by weight. It was mixed in a magnetic stirrer at 50°C for 30 minutes. The A1 and A2 added compositions, THF and DMF, added at a ratio of (1:1) by weight and mixed, and then PVDF was added at the rate of 5.0% of the total mixture weight. Alumina was weighed in the specified proportions, then added to the mixture and stirred at 50°C for 60 minutes. In order to mix the alumina powders more homogeneously, the mixing duration increased to 60 minutes. The mixture was applied with a spray on the ceramic substrates and cured in an oven at 100°C for 2 hours. Details and sample codes of the prepared compositions are given in Table 2.

Table 2

Details of the compositions
Sample Code	Weight ratio (PVDF:Al₂O₃)
PVDF	-
PVDF-0.1-A1	(1:0.1)
PVDF-0.25-A1	(1:0.25)
PVDF-0.5-A1	(1:0.5)
PVDF-1.0-A1	(1:1)
PVDF-0.1-A2	(1:0.1)
PVDF-0.25-A2	(1:0.25)
PVDF-0.5-A2	(1:0.5)
PVDF-1.0-A2	(1:1)

2.2. Characterization of the coatings

The hydrophobicity of the coating was characterized using the water angle (CA) measurement. The (CA) was measured using KSV CAM 200 contact angle meter. Droplets of volume 1µLwas used for measuring the (CA) values. Results are average values from 4 different regions of each sample.

The surface topography of the coatings was evaluated by Atomic Force Microscopy (Digital Instruments NanoScope IV AFM Device). Surface scans of 1µm² square areas were performed at 22°C in the atmosphere for different sample positions with a scanning rate of 1.51 Hz. The mean roughness values (Ra) were calculated as the average 10 AFM scans of different regions of the sample.

Glossiness values of the samples were determined using a Multi-Gloss 268 model gloss-meter. Glossiness values of the samples were measured at three different degrees, 20, 60, and 85 degrees. The coloring parameters of the samples was measured by a spectrometer (Minolta CR, 300 Colormeter). The colorimeter operates on the CIELab method, which is utilized technique in the ceramic roduction to determine the whiteness and color of the tiles by measuring three main parameters (Hunter parameters) L* (brightness) from absolute white L*= 100 to absolute black L *= 0, a* (red–green), b* (yellow–blue)

elaborated from the visible spectra.

Fourier Transform Infrared Spectroscopy (FTIR) was used to determine the chemical bonds. The ATR method was used to evaluate the functional groups that provide hydrophobic fuctionality of the coatings.

The microstructures of the samples were examined by scanning electron microscopy (SEM) analysis. Firstly, the surface of the samples was made suitable for SEM analysis by grinding with a series of SiC abrasive papers and then polished using diamond paste. Then the sample surfaces were coated with gold. For the coating thickness, images were taken from the cross-sections of the samples, and the coating thicknesses were examined.

Brush tests were carried out to evaluate the adhesion performance of the coating to the substrates. The samples wiped off with a dry cloth before starting the test. Samples were prepared 10x20 cm² dimensions. Brushing cycles with a nylon brush and deionized water were applied by Elcometer 1720 washability tester. Coating integrity was visually checked at the end of every 500 cycles. It was continued up to 2500 cycles with the samples that preserved the surface integrity and then the contact angles were measured. Measurements were made from 4 different places of the samples and the average values were taken.

Since hydrophobic surfaces also exhibit ice-repellent properties [27], anti-icing tests were also performed on the samples. The icing test was carried out in an air-conditioning cabinet where the temperature reached (-15°C). Before starting the test, the samples were conditioned at (-15°C) for 60 minutes. The samples were fixed approximately 15 cm above the floor of the cabinet. Droplets cooled temperature close to 0°C were sprayed onto the pieces by a spray with a nozzle diameter of 1mm. Samples were weighed every 5 minutes to see the ice accumulation until 90 minutes.

3.1. FTIR analysis of the samples

FTIR analyzes were performed on the coated samples, and it was checked whether the surface chemical structure changed. The (-CF₂) group is known to increase the hydrophobicity of the surface [28]. It was observed that the (-CF₂) group was present on the PVDF-coated surface. In order to determine whether the alumina additive deteriorates the PVDF structure, FTIR analyzes of the samples coated with the Al₂O₃/PVDF composites were performed (Fig. 1).

The existence of typical bonds (658, 875, 1385 cm^− 1) confirmed that PVDF polymer was present. The peaks at 1385 and 875 cm^− 1 are attributed to the stretching vibration of C-H and C–F in PVDF structure, respectively [29]. The absorption peaks at 1090 and 1065 cm^− 1 was the C–H stretching vibration [30]. Vibrational bands at 658 cm^− 1 refer to C-F bending [31]. The band at 1499 cm^− 1 is assigned to C-H bending [32]. Figure 1 shows that there is no significant change in PVDF functional groups after Al₂O₃ addition [33]. Due to the absence of typical O-Al-O bond at 550 and 950 cm^− 1 in the coatings we can conclude that there is absence of any chemical bonds between PVDF and alumina particles [34].

3.2. Contact angle measurements

In the study, contact angles of coated and uncoated samples were measured. The contact angle measurement image of the uncoated sample is given in Fig. 2 (a). This sample has a contact angle of 12.34°±0.02 [35]. After coating with additive-free PVDF, the contact angle of the sample increased to 101.19°±0.02 [36].

The contact angles of the PVDF coated specimens doped with A1-type alumina are given in Fig. The contact angle decreased to 93.93°±0.02 with the addition of 0.1% by weight of alumina (A1 type). With the addition of 0.25 percent alumina, this value increased slightly and reached 95.87°±0.02. With the A1 type alumina ratio reaching 0.5% and 1.0% by weight, the contact angle values of the samples are 85.44°±0.02 and 81.37°±0.02, respectively. It was observed that the addition of alumina, significantly higher than 0.25% by weight, decreased the contact angle value.

The contact angles of the coatings made with the addition of alumina (A2), which has a more refined particle size distribution than the A1 sample, were also measured (Fig. 3) With the addition of 0.1% alumina (A2) weight, the contact angle of the coating is 134.33°±0.02. When the addition rate reached 0.25%, the superhydrophobic property was obtained, and the contact angle value reached 162.46°±0.02. The increase in the A2 ratio caused a decrease in the contact angle. Adding 0.5% by weight reduced the contact angle value to 126.78 ± 0.02, and the minimum contact angle was reached with the addition of 1.0% (105.38°±0.02).

The hydrophobic property obtained by adding A1 alumina with an average particle size of 69.60 ± 0.5µm is less than the hydrophobic property acquired by adding A2 alumina with an average particle size of 3.97 ± 0.5µm (Fig. 4). Edeh et al. reported that hydrophobicity increased with decreasing particle size in their study with biochar [37]. Lakshmi et al. found that small particle size increases roughness and therefore hydrophobicity [38].

3.3. Surface topography & average roughness values

The surface topographies and the samples' mean roughness values (Ra) were measured with an AFM device's help. The Ra values obtained by adding A1-type alumina to the PVDF coating composition are given in Fig. 5. The mean roughness value of the PVDF coated sample is 5.07 ± = 0.5 nm. When A1-type alumina is added to the PVDF composition, the average roughness value increases. The addition of 1% by weight of A1-type alumina reached its maximum, and the average roughness value increased to 37.72 ± = 0.5 nm.

A2-type alumina is also added to PVDF coatings. The roughness values obtained by adding A2-type alumina are presented in Fig. 6. The mean roughness value was 5.07 ± 0.5 nm at the addition of 0.1% by weight of A2-type alumina. As the amount of A2-type alumina added increased to 1.0% by weight, the roughness value reached 13.56 ± 0.5 nm. Since A2 type alumina has a more refined particle size distribution than A1 type alumina, its roughness value is lower.

Wettability, which is one of the important properties of a solid surface, is closely related to the geometry, chemical composition and roughness of the solid surface [39]. Particularly, nano-sized roughnesses are critical to obtain samples with high contact angles. In particular, this situation, known as the lotus effect, is achieved by homogeneously dispersing nano-sized roughnesses on the surface. In the study, the sample with the highest contact angle is the samples containing 0.25 weight percent alumina. These samples' surface topography are given in Fig. 7. These images show a more significant roughness in the A1 type doped PVDF coating (Fig. 7 (a). However, the roughness distribution is not homogeneous. On the other hand, in the A2-type doped coating (Fig. 7 (b), a more delicate roughness was obtained and homogeneously on the surface. These results explain why this coating has a higher contact angle.

Muhamad et al. reported that nanoscale surface roughness has a significant effect on contact angles as a result of their work with PVDF-bentonite hollow fiber [40]. Wang et al. also found that the rougher the hydrophobic calcite surface, the more hydrophobic it is [41]. But roughness alone is not sufficient for high hydrophobicity, the roughness must be homogeneous. Mendoza et al. stated that the source of the higher hydrophobicity of the PDMS sample is the homogeneous roughness and distribution of air cavities in the sample [42]. Cui et al. thorn-like protrusions were observed on the surface of their coating as a result of SEM, providing sufficient roughness for superhydrophobicity and they mentioned that uniformity of the surface is a key factor to provide a superhydrophobic coating [43]. It is clearly seen that the roughness in Fig. 7(b) is more uniform than in Fig. 7(a). This result is the reason for the high superhydrophobicity.

3.4. Microstructural analysis

Figure 8 refers to the microstructure image of the PVDF-coated ceramic tile surface. The contact angle of this sample is 101.9°±0.02. It is seen that the PVDF coating is coated on the surface relatively homogeneously.

The microstructure images obtained with the addition of A1-type alumina are presented in Fig. 9. In the PVDF-0.1-A1 sample, the alumina particles getting agglomerated and could not be distributed homogeneously on the surface. This microstructural property explains the decrease in the contact angle relative to the PVDF-coated sample (Fig. 9(a)). In the PVDF-0.25-A1 microstructure (Fig. 9(b)), alumina particles are more homogeneous in the microstructure. This effect slightly increased the contact angle compared to the 0.1% wt added sample. When the alumina ratio reaches 0.5% (Fig. 9(c)). it is seen that various pores are formed in the microstructure and can not fully cover the surface. When the alumina ratio comes to its maximum value (%1.0), it is seen that alumina forms large lumps and cannot provide a homogeneous distribution on the surface (Fig. 9(d)).

Microstructure images of A2-type alumina added samples are given in Fig. 10. A very homogeneous microstructure is observed in the sample with the addition of 0.1% by weight of alumina. When the ratio by weight is 0.25%, alumina particles are homogeneously distributed on the surface [44]. At rates higher than 0.25%, it was observed that the particles were agglomerated [45]. Particularly when the weight ratio reaches 1.0%, it is seen that the particles come together to form clusters, and they tend to form surface defects (separation of particles, porosity, and similar discontinuities) in the coating.

3.5. Glossiness and coloring parameters of the samples

The gloss and color parameters of the coated samples were also measured (Table 3). The brightness values of the uncoated sample at 20, 60, and 85° are 73°±1, 81°±1, and 83°±1, respectively. Considering the color values, L*, a*, and b* are 89.7 ± 0.1,-0.51 ± 0.1, and 1.53 ± 0.1, respectively. By coating the glossy white tile surface with PVDF, a slight decrease was observed in the gloss value. The gloss values at 20, 60, and 85° were obtained as 70 ± 1, 79 ± 1, and 80 ± 1 values, respectively. As for the color value, there is no significant change compared to the uncoated sample.

By doping A1-type alumina to PVDF, there are differences in the gloss and color values of the coating compared to the undoped sample. It reduces the gloss value and makes the surface dull, especially compared to PVDF with 1.0 percent by weight alumina added (PVDF-1.0-A1). The color values of the A1 type alumina additive caused an increase in the L* value, mainly due to its whitening effect [46]. The addition of 0.1% by weight of A2 type alumina (PVDF-0.1-A2) did not cause a change in the gloss and opacity values compared to pure PDVF. The opacity increased in general with the addition of A2 more than this ratio. An increase was observed in color values, especially in whiteness value (L*).

When we compare the effects of both types of alumina additives, it is seen that the A1 sample with coarser particles increases the opacity more. The addition of A2 type alumina, which has a more refined particle size distribution, decreased the brightness less than A1. In the color values, after 0.25% by weight, there is a slight decrease in the L value. This effect suggests that the A2-type alumina is not homogeneously dispersed or agglomerated. For this, microstructure analyzes were examined, and a detailed examination was made.

Table 3

Glossiness and coloring parameters of the samples
Samples	Gloss Values			Colour Values
Samples	20°	60°	85°	L*	a*	b*
Uncoated Sample	73 ± 1	81 ± 1	83 ± 1	89.7 ± 0.1	-0.51 ± 0.1	1.53 ± 0.1
PVDF	70 ± 1	79 ± 1	80 ± 1	89.4 ± 0.1	-0.50 ± 0.1	1.51 ± 0.1
PVDF-0.1-A1	69 ± 1	78 ± 1	79 ± 1	89.5 ± 0.1	-0.48 ± 0.1	1.47 ± 0.1
PVDF-0.25-A1	68 ± 1	76 ± 1	77 ± 1	89.9 ± 0.1	-0.46 ± 0.1	1.45 ± 0.1
PVDF-0.5-A1	65 ± 1	73 ± 1	75 ± 1	90.2 ± 0.1	-0.44 ± 0.1	1.42 ± 0.1
PVDF-1.0-A1	62 ± 1	70 ± 1	71 ± 1	90.5 ± 0.1	-0.43 ± 0.1	1.39 ± 0.1
PVDF-0.1-A2	70 ± 1	79 ± 1	80 ± 1	89.5 ± 0.1	-0.49 ± 0.1	1.50 ± 0.1
PVDF-0.25-A2	69 ± 1	78 ± 1	79 ± 1	90.6 ± 0.1	-0.36 ± 0.1	1.29 ± 0.1
PVDF-0.5-A2	67 ± 1	74 ± 1	77 ± 1	90.1 ± 0.1	-0.38 ± 0.1	1.31 ± 0.1
PVDF-1.0-A2	64 ± 1	71 ± 1	74 ± 1	89.7 ± 0.1	-0.39 ± 0.1	1.30 ± 0.1

3.6. Abrasion (brush) test

Abrasion tests were carried out by carrying out brush tests of coated samples [47]. As a result of the brush tests carried out up to 2500 cycles, no result such as peeling the coating from the surface was obtained. Wear test and after contact angle measurements were made. The results obtained are in Fig. 11. A significant decrease was observed in contact angles after the wear test in A1-type alumina added coatings. In the coatings made with A2-type alumina, a lesser decrease in contact angle was detected due to the abrasion test compared to the A1 samples. After the abrasion test, A2 doped coatings retained their hydrophobic properties (contact angle values greater than 90 degrees). In particular, the sample with 0.25% by weight A2 doped continued to show superhydrophobic properties after abrasion. (The contact angle value is higher than 150°).

3.7. Anti-icing test

Icing tests were conducted to determine how well the coatings on ceramic substrates prevent icing. The icing test was carried out in the air-conditioning cabinet. Whether the sprayed water drops form ice on the coated surfaces at -15°C was determined by taking the weight of the tiles every 5 minutes [48, 49]. The test was continued for up to 90 minutes. The weight-time graph obtained according to the samples is presented in Fig. 12. Since the tile surface was hydrophilic (CA: 12.34 ± 0.02), water droplets easily dispersed on the surface and showed a tendency to frost. Especially in the first 10 minutes, it started to ice quickly. No icing was detected on the surfaces in PVDF coated, and alumina was added to samples until the first 40 minutes. PVDF/Al₂O₃ coatings possessed good icing delay ability [50]. However, it was observed that the coatings containing 0.5% and 1.0% by weight A1 type alumina started to the ice after the first 30 minutes. Since these samples did not show hydrophobic properties, the water drops adhered to the surface after a certain period.

Al₂O₃/PVDF composites with different particle sizes were applied to the ceramic surfaces. PVDF, which is a kind of fluoropolymer, has been preferred to provide hydrophobicity to the surface. However, it alone was not sufficient to provide superhydrophobicity because a rough surface is required. Alumina powders with two different particle sizes were used to provide roughness.

A homogeneous distribution could not be obtained in PVDF coatings added to coarse particle size A1-type alumina. A more homogeneous distribution was observed in the PVDF coatings added to the fine-particleed A2-type alumina. AFM and SEM results are in agreement with each other and confirm these results. While the contact angle of the uncoated ceramic substrate was 12.34°±0.02, it increased to 101.9°±0.02 after being coated with pvdf. A1 type alumina provided roughness to the coating, but due to lack of homogeneity, the contact angle decreased to 95.87°±0.02. The contact angle increased to 162.46°±0.02 as A2 type alumina both added roughness and homogeneity to the coating.

The addition of A2 type alumina, which has a more refined particle size distribution, decreased the brightness less than A1. After the wear test, less reduction in contact angle was detected in the coatings made with A2 type alumina compared to the A1 samples. After the wear test, the A2 doped coatings retained their hydrophobic properties. The 0.25% by weight A2 type alumina doped sample showing superhydrophobic property continued to show this feature even after the wear test was applied. PVDF/Al₂O₃ composites have good anti-icing ability and no icing was observed on the PVDF/Al₂O₃ composites as a result of the icing test.

In conclusion; superhydrophobicity and anti-icing properties are provided to ceramic surfaces coated with PVDF coated with 0.25% A2 type alumina by weight. It has also successfully passed the color and abrasion tests required for this coating to be used as a product.

Funding

The authors declare that no funds, grants, or other support were received during the preparation of this manuscript

Competing Interest

The authors have no relevant financial or non-financial interests to disclose.

Author Contributions

Neslihan Tamsü Selli and Neslihan Basaran contributed to the study conception and design. Material preparation, data collection and analysis were performed by Didem Samsun and Sena Alkan. The first draft of the manuscript was written by Neslihan Tamsü Selli and Neslihan Basaran commented on previous versions of the manuscript. All authors read and approved the final manuscript and final manuscript supervised by Neslihan Tamsu Selli.

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Preparation of superhydrophobic coating with excellent abrasion resistance and anti-icing properties using Al2O3/PVDF composites with different Al2O3 particle sizes

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Abstract

Figures

1. Introduction

2. Experimental Procedure

2.1. Materials and coating solution preparation

2.2. Characterization of the coatings

3. Results And Discussion

3.1. FTIR analysis of the samples

3.2. Contact angle measurements

3.3. Surface topography & average roughness values

3.4. Microstructural analysis

3.5. Glossiness and coloring parameters of the samples

3.6. Abrasion (brush) test

3.7. Anti-icing test

4. Conclusions

Declarations

References

Additional Declarations

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