Waterborne polyurethane (WBPU) coatings represent eco-friendly alternatives to solvent-based systems due to their low volatile organic compounds (VOCs) emissions and reduced toxicity. However, their inherent hydrophilicity limits water repellence, thereby restricting their use in demanding environments. In this research, pristine calcium carbonate (CaCO3), sodium stearate-modified CaCO3 (SS-CaCO3), and a mixture of SS-CaCO3 with silica nanoparticles (SiO2NPs) improved the hydrophobicity of WBPU. Four formulations, namely, pristine WBPU (P1), WBPU+CaCO3 (P2), WBPU + SS-CaCO3 (P3), and P3 + SiO2NPs (P4), were prepared and applied onto mild steel substrates. The composite formation was confirmed using Fourier-transform infrared (FTIR) spectroscopy, with the intensity of the O-H band in P4 being lower. According to the X-ray diffraction (XRD) study, the dispersion of the SiO2NPs in P4 was improved, which reduced the crystallite size to 22.38 nm. The scanning electron microscope (SEM) images indicated that the surface roughness of P4 increased with the enrichment of SiO2NPs on the surface of the coating. The spectroscopic evidence of the energy-dispersive X-ray (EDX) spectroscopy revealed the corresponding elemental distribution and a higher proportion of oxygen. The measurements of water contact angle (WCA) showed that P4 had the best hydrophobicity (105.08 ± 0.74°), which can be explained by the fact that P4 possessed the best surface roughness produced by the nanoparticles. These results indicate that the presence of SS-CaCO3 and SiO2NPs enhances the performance and water repellence of WBPU, which further improves its prospects as an environmentally friendly coating.


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