Fouling
and accretion have negative impacts on a plethora of processes.
To mitigate heterogeneous nucleation of a foulant, lowering the surface
energy and reducing surface roughness are desired. Here, we develop
a multilayer coating to mitigate solution-based heterogeneous fouling
for internal flows. The first layer is a sol–gel silicon dioxide
(SiO2) coating, which acts as a corrosion barrier, creates
the surface chemistry needed for covalent bonding of the slippery
omniphobic covalently attached liquid (SOCAL), and ensures an atomically
smooth (<1 nm) interface. The second layer bonded to SiO2 is SOCAL, which further reduces the nucleation rate due to its low
surface energy (<12 mJ/m2). The presence of a consistent
sol–gel SiO2 base coating to bind to the SOCAL enables
application to various metallic substrates. The coating is solid,
making it more durable when compared to alternative slippery liquid-infused
surfaces (LIS) that suffer from lubricant loss. To demonstrate performance
and scalability, we apply our coating to the internal walls of aluminum
(Al) tubing and test its fouling performance in a flow-fouling setup
with single-phase flow of synthetic seawater. The seawater consists
of saturated calcium sulfide (CaSO4), and fouling is characterized
in both laminar and turbulent flow regimes (Reynolds numbers 1030
to 9300). Our coating demonstrated a reduction in salt scale fouling
by 95% when compared to uncoated Al tubes. Furthermore, we show our
coating to withstand turbulent flow conditions, mechanical abrasion
loading, and corrosive environments for durations much longer than
LIS. Our work demonstrates a coating methodology applicable to a variety
of metal substrates and internal passages to achieve antifouling in
single-phase flows.