| Summary: | Corrosion, a significant industrial issue causing material and economic losses, can be mitigated by hydrophobic coatings. This study develops a SiO₂-MnO₂/Polyethylene (PE) coating reinforced with stearic acid to enhance corrosion resistance, synthesized via a one-step hydrothermal method at 110–140 °C. The coating was immersed in stearic acid for 0.5, 1, and 5 min to optimize hydrophobicity and durability. Characterization involved X-Ray Diffraction (XRD) for crystal structure, Scanning Electron Microscopy (SEM) for morphology, and Fourier Transform Infrared Spectroscopy (FTIR) for functional groups, with contact angles measured by DSLR camera and corrosion tested in 1 % NaCl. Decay rate (k) was monitored over 7 days, and corrosion rate determined via weight loss. Without stearic acid, the coating achieved a contact angle of 138.4° at 130 °C. Post-reinforcement, the 1 min immersion at 130 °C peaked at 141.15° but exhibited the highest decay rate (0.022 °/day) and a corrosion rate of 0.16 mm/year, indicating strong initial hydrophobicity but rapid degradation. Conversely, the 5 min immersion yielded the lowest decay rate (0.019 °/day) and corrosion rate (0.11 mm/year), reflecting superior stability and protection from a thicker, aggregated structure, despite a 133.4° contact angle. The 0.5 min sample showed intermediate results (0.020 °/day, 0.18 mm/year). Unlike prior studies prioritizing initial hydrophobicity, this work highlights the role of coating thickness, stability, and synthesis conditions in achieving long-term corrosion resistance, providing novel insights for industrial applications.
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