Abstract:
Amorphous alloy coatings offer outstanding mechanical properties, corrosion resistance, and soft magnetic performance, showing great potential in aerospace, marine engineering, and the energy and chemical industries. However, the inherent difficulty in controlling surface wettability significantly limits their service performance in harsh environments. Combining amorphous alloy coatings with hydrophobic surfaces to achieve a synergistic "structure–function integration" advantage has become a research focus in surface engineering. This paper systematically reviews the progress in this field, with emphasis on three mainstream preparation technologies thermal spraying, laser cladding, and cold spraying as well as three key factors governing hydrophobicity: surface micromorphology and roughness, surface chemical composition and energy, and coating porosity and defects. The comparative analysis reveals distinct characteristics among the three preparation technologies: thermal spraying offers high efficiency and suitability for large-area applications but tends to introduce porosity and partial crystallization; laser cladding produces highly dense coatings with metallurgical bonding yet suffers from high equipment cost and parameter sensitivity; cold spraying maximally retains the amorphous structure with low oxidation, though deposition efficiency is constrained by powder plasticity. Hydrophobic properties are primarily regulated through three mechanisms: the Wenzel-to-Cassie-Baxter wetting state transition, where an optimal roughness range exists for stable air pocket entrapment; the interplay between surface oxidation and elemental segregation, in which oxidation-induced polar groups compete with the intrinsically low surface energy of amorphous alloys; and the pore pinning effect, where excessive porosity simultaneously degrades barrier capability and air layer stability. Core surface modification techniques including chemical or electrochemical etching, inorganic–organic hybrid sealing treatments, and laser texturing have been extensively investigated, with rational process parameter optimization identified as the essential pathway to achieving high-performance superhydrophobic amorphous alloy coatings. Despite significant progress, current research still confronts considerable challenges: the long-term hydrophobic durability under coupled mechanical wear, corrosion, and UV exposure remains inadequately evaluated; the inherent conflict between oxidation-induced hydrophilicity and the desired hydrophobic state resists facile resolution; industrially scalable modification technologies for complex-shaped workpieces remain scarce; and the structure-property relationships linking glass-forming ability, thermal stability, and mechanical performance to hydrophobic behavior are yet to be clarified. Future efforts should prioritize the development of composite modification strategies, the systematic optimization of coating compositions and processes through high-throughput screening and machine learning, and the investigation of service behavior in typical application scenarios such as anti-icing, self-cleaning, and oil-water separation. These advances will provide essential support for the engineering application of high-performance hydrophobic amorphous alloy coatings.