A robust, hydrophobic CeO2/NiCoCrAlY composite coating with excellent thermal stability and corrosion resistance prepared by air plasma spray.

Hydrophobic coatings based on organic or ceramic materials usually suffer from low wear resistance and poor thermal stability, which limit their practical applications. Here we report a robust, hydrophobic CeO 2 /NiCoCrAlY composite coating prepared by air plasma spraying (APS), which shows superior wear resistance, excellent high-temperature stability and high bonding strength with the substrate. The coating can maintain its hydrophobicity after abrasion under 10 kPa over a 4 m distance, or after annealing at 773 K for 8 h. It also presents good corrosion resistance to protect the metallic substrate under corrosive working conditions. The CeO 2 /NiCoCrAlY composite coating provides a reliable and effective route to fabricate hydrophobic surfaces which may have potential applications in harsh environments. • CeO 2 /NiCoCrAlY composite coatings were prepared by APS. • The coating with 80% CeO 2 can maintain its hydrophobicity after abrasion under 10 kPa over a 4 m distance. • The coating with 80% CeO 2 can also maintain its hydrophobicity after annealing at 773 K for 8 h. • The coating can protect the substrate from corrosion. • The robust, hydrophobic and thermally-stable coating is promising to work under harsh environments. [ABSTRACT FROM AUTHOR]