This work presents a novel coating technique to manufacture ceramic superhydrophobic coatings rapidly and economically. A rare earth oxide (REO) was selected as the coating material due to its hydrophobic nature, chemical inertness, high temperature stability, and good mechanical properties, and deposited on stainless steel substrates by solution precursor plasma spray (SPPS). The effects of various spraying conditions including standoff distance, torch power, number of torch passes, types of solvent and plasma velocity were investigated. The as-sprayed coating demonstrated a hierarchically structured surface topography, which closely resembles superhydrophobic surfaces found in nature. The water contact angle on the SPPS superhydrophobic coating was up to 65% higher than on smooth REO surfaces.
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