One-step fabrication of hydrophobic yttria stabilized zirconia - Polytetrafluoroethylene – Silicone composite coating with considerable anti-wear and anti-corrosion properties

A novel yttria stabilized zirconia (YSZ) - polytetrafluoroethylene (PTFE) - silicone composite coating was fabricated by the atmospheric plasma spraying (APS). Results showed that this coating exhibited dense texture and surface uplift feature due to the thermal-mechanical shock synergistic effect, and showed good hydrophobicity with a contact angle of 150.65°. The sliding wear test confirmed that the coating showed excellent self-lubricating property, reflected by a low friction coefficient of 0.12. This coating also showed good marine weatherability, and possessed excellent corrosion resistance with a high potential which a value is closed to 0 V. These current results clearly demonstrated that APS technique possessed a huge advantage for the one-step fabrication of the ceramic doped PTFE-based composite coating with considerable wear resistance and corrosion resistance. •The polytetrafluoroethylene based composite coating was fabricated by APS.•Thermal-mechanical shock synergistic effect resulted in dense growth texture.•The coating exhibited excellent self-lubricating effect and hydrophobicity.•The coating showed considerable marine weatherability and corrosion resistance.