Fabrication of Hierarchical Patterned Surfaces Using a Functionalized CeO₂-EPDM Composite for Crevice Corrosion Prevention on High-Voltage Insulators

Crevice corrosion accounts for 62% of the recorded breakdown of insulators utilized in transmission lines, which may interfere with the reliability of power utilities. To address these challenges, sustainable and resilient slippery lubricant-infused porous surfaces (SLIPS) are developed on insulators to prevent electrochemically/biochemically induced crevice corrosion especially occurring in tropical and coastal environments. The conventional way of developing SLIPS by chemical and physical etching might interfere with the mechanical stability of insulators composed of pin (galvanized steel), cement, and shell (porcelain). The current study proposes a noble concept of developing hierarchical patterned textured surfaces on insulators to fabricate a resilient SLIPS coating without physical/chemical etching. The proposed coating exhibits 99% antiadhesion performance against a mixed culture of bacterial strains, superior hydrophobicity (contact angle: 160°, contact angle hysteresis: 4°), and crevice corrosion resistance performance at elevated temperatures (25-75 °C) and humidity. This study could facilitate a new route for the development of sustainable and highly reliable SLIPS coatings in the future.