One-Step Electrodeposition of Superhydrophobic Coatings on Steel: Influence of Process Parameters

Steel is inherently susceptible to corrosion due to its hydrophilic nature (water contact angle < 90°). This study developed superhydrophobic coatings (water contact angle > 150°) using a one-step electrodeposition method, a simple and cost-effective approach that simultaneously enhances surface roughness and lowers surface energy using non-polar chemicals. The fabrication process was optimized using the Taguchi method experimental design and statistically validated with ANOVA, assessing the impact of current density, salt concentration ratio, electrodeposition time, and reagent concentration on surface wettability. Results confirmed that current density and salt concentration ratio significantly influenced the water contact angle on the surface of the deposited coatings. After 13 days of exposure to atmospheric conditions, the coating layer produced with optimum conditions experienced a minor reduction in its superhydrophobic performance while still retaining its classification as superhydrophobic.