%0 Journal Article %A Gateman, SM %A Page, K %A Halimi, I %A Nascimento, ARC %A Savoie, S %A Schulz, R %A Moreau, C %A Parkin, IP %A Mauzeroll, J %D 2020 %F discovery:10090631 %J ACS Applied Materials and Interfaces %K high-velocity oxygen fuel, thermal spray, coatings, stainless steel, superhydrophobicity, surface chemistry, corrosion %N 1 %P 1523-1532 %T Corrosion of One-Step Superhydrophobic Stainless-Steel Thermal Spray Coatings %U https://discovery.ucl.ac.uk/id/eprint/10090631/ %V 12 %X As most superhydrophobic coatings are made of soft materials, the need for harder, more robust films is evident in applications where erosional degradation is of concern. The work herein describes a methodology to produce superhydrophobic stainless-steel thermal spray coatings using the high-velocity oxygen fuel technique. Due to the use of a kerosene fuel source, a carbon-rich film is formed on the surface of the thermal spray coatings, lowering the surface energy of the high-energy metallic substrates. The thermal spray process generates a hierarchical micro-/sub-micro-structure that is needed to sustain superhydrophobicity. The effect of spray parameters such as particle velocity and temperature on the coating’s hydrophobicity state was explored, and a high particle velocity was shown to cause superhydrophobic characteristics. The coatings were characterized using scanning electron microscopy, profilometry, X-ray photoelectron spectroscopy, static water contact angle measurements, water droplet roll-off measurements, and water droplet bouncing tests. The corrosion behavior of the coatings was studied using potentiodynamic polarization measurements in order to correlate water repellency with corrosion resistance; however, all coatings demonstrated active corrosion without passivation. This study describes an interesting phenomenon where superhydrophobicity does not guarantee corrosion resistance and discusses alternative applications for such materials. %Z This version is the author accepted manuscript. For information on re-use, please refer to the publisher’s terms and conditions.