Simple and scalable synthesis of super-repellent multilayer nanocomposite coating on Mg alloy with mechanochemical robustness, high-temperature endurance and electric protection

Multi-functionalization is the future development direction for protective coatings on metal surface, but has not yet been explored a lot. The effective integration of multiple functions into one material remains a huge challenge. Herein, a superhydrophobic multilayer coating integrated with multidimensional organic-inorganic components is designed on magnesium alloy via one-step plasma-induced thermal field assisted crosslinking deposition (PTCD) processing followed by after-thermal modification. Hard porous MgO ceramic layer and polytetrafluoroethylene (PTFE) nano-particles work as the bottom layer skeleton and filler components separately, forming an organic-inorganic multilayer structure, in which organic nano-particles can be crosslinked and cured to form a compact polymer-like outer layer with hierarchical surface textures. Remarkably, the chemical robustness after prolonged exposure to aqua regia, strong base and simulated seawater solution profits from polymer-like nanocomposite layer uniformly and compactly across the film bulk. Moreover, the self-similar multilayer structure coating endows it attractive functions of strong mechanical robustness (>100th cyclic rotary abrasion), stable and ultra-low friction coefficient (about 0.084), high-temperature endurance, and robust self-cleaning. The organic-inorganic multilayer coating also exhibits high insulating property with breakdown voltage of 1351.8 ± 42.4 V, dielectric strength of 21.4 ± 0.7 V/µm and resistivity of 3.2 × 10¹⁰ Ω·cm. The excellent multifunction benefits from ceramic bottom skeleton, the assembly and deposition of multidimensional nano-particles, and the synergistic effect of organic inorganic components. This study paves the way for designing next generation protective coating on magnesium alloy with great potential for multifunctional applications.