The low mechanical durability of superhydrophobic surfaces has been considered as a serious limitation to develop these unique coatings in industrial applications. Despite the promising results, the main challenges are related to the fabrication of stable and practical superhydrophobic coatings with proper adhesion using the facile approaches. In the present study, the superhydrophobic surface was fabricated using the two-step spray method with a WCA of 160°. At the first step of this method, the hydrophobic resin was sprayed as an adhesive layer. Then, at the next step, the stearic acid-modified Alumina nanoparticles were sprayed on the adhesive layer. Important coating parameters such as stability of spray suspension and thermal stability of coating were investigated. The results showed that the decreasing agglomeration rate of particles during the spraying enhances the more uniform distribution and hydrophobicity of the layer. Besides, increasing the temperature, especially after 250 °C, reduced the roughness and hydrophobicity of the layers due to the decomposition of stearic acid. Meanwhile, molecular dynamics (MD) simulation was applied to investigate the adsorption of stearic acid on the Alumina surface along with its interaction with water molecules. The results can propose the effective mechanism of suspension stability and thermal stability on the growth and formation of coatings. Also, the findings of this study can help to fabricate superhydrophobic coatings on various substrates using the two-step spray method with wear resistance.

超疏水表面的低机械耐久性被认为是在工业应用中开发这些独特涂层的严重限制。尽管取得了有希望的结果，但主要挑战与使用简便方法制造具有适当附着力的稳定且实用的超疏水涂层有关。在本研究中，超疏水表面是使用两步喷涂法制造的，WCA 为 160°。在该方法的第一步中，将疏水性树脂作为粘合剂层进行喷涂。然后，在下一步中，将硬脂酸改性的氧化铝纳米颗粒喷涂在粘合剂层上。研究了重要的涂层参数，例如喷涂悬浮液的稳定性和涂层的热稳定性。结果表明，喷涂过程中颗粒团聚率的降低增强了涂层更均匀的分布和疏水性。此外，提高温度，特别是在 250°C 之后，由于硬脂酸的分解，降低了层的粗糙度和疏水性。同时，应用分子动力学（MD）模拟来研究硬脂酸在氧化铝表面的吸附及其与水分子的相互作用。结果可以提出悬浮稳定性和热稳定性对涂层生长和形成的有效机制。此外，这项研究的发现有助于使用具有耐磨性的两步喷涂方法在各种基材上制造超疏水涂层。