Superhydrophobic Coatings with High Robustness and Green Environmentally Friendly Characteristics: Structures, Mechanisms, and Engineering Applications

Abstract

Superhydrophobic coatings are promising for self-cleaning, anti-icing, anticorrosion, and oil–water separation, but practical use is limited by fragile micro/nanostructures and persistent fluorinated chemicals. This review examines four complementary strengthening mechanisms: interfacial chemical bonding, armor protection, stress dissipation, and self-healing. Quantitative criteria involving energy-release-rate balance, the Cassie–Wenzel wetting-state transition, and geometric constraints on armor structures link material design to mechanical and wetting stability. Applications in environmental remediation, infrastructure protection, energy equipment, and household textiles are then discussed. Finally, existing performance evidence for fluorinated and fluorine-free coatings is compared, and the feasibility and sustainability of scalable manufacturing are briefly evaluated in terms of material hazards, cost, and end-of-life management. By integrating physical structures, toughening mechanisms, and engineering applications, this framework provides guidance for developing environmentally responsible and durable superhydrophobic coatings.