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Materials Chemistry and Physics: Jure Zigon, Matja Z Pavli C, Marko Petri C, Sebastian Dahle
Materials Chemistry and Physics: Jure Zigon, Matja Z Pavli C, Marko Petri C, Sebastian Dahle
H I G H L I G H T S
• Enhanced wettability of MDF substrate with coating achieved with air discharge.
• Introduction of standard and non-standard surface evaluation methods.
• Plasma treatment reduced surfaces color and gloss changes during weathering.
• No influence of plasma treatment on mechanical properties of surface system.
A R T I C L E I N F O A B S T R A C T
Keywords: A non-thermal plasma treatment generated in air at atmospheric pressure was used for surface modification of
Coating medium density fiberboard (MDF) substrate. Untreated and plasma-treated substrates were coated with a
Medium density fiberboard waterborne acrylic coating and exposed to accelerated artificial weathering (AAW) in interior mode. Plasma
Plasma
treatment increased the surface free energy of MDF by about 50%, which positively influenced on the wettability
Surface
Weathering
of the MDF with the coating. Weathering of the coated MDF caused a decrease in surface gloss and color changes,
which were less pronounced for plasma-treated samples. Attenuated total reflection Fourier transform infrared
spectra and microscopic analysis revealed degradation of the acrylic resin on the coated MDF due to light
irradiation during weathering. After 250 h of weathering, the surface roughness of the coated MDF increased by
about 3 μm. The coated MDF surfaces started to lose their hydrophobic character after 50 h of weathering.
Finally, the determination of mechanical properties showed that coated MDF became more resistant to scratching
during AAW, while the adhesion of the coating film to the MDF substrate was not affected in a significant trend
with time of AAW. In both cases, no influence of plasma treatment was detected.
https://doi.org/10.1016/j.matchemphys.2021.124358
Received 9 August 2020; Received in revised form 4 January 2021; Accepted 3 February 2021
Available online 9 February 2021
0254-0584/© 2021 The Authors. Published by Elsevier B.V. This is an open access article under the CC BY license (http://creativecommons.org/licenses/by/4.0/).
J. Žigon et al. Materials Chemistry and Physics 263 (2021) 124358
Fig. 1. The sketch of the plasma setup and photos of generated different plasma discharges: (a) without substrate, (b) treatment of beech wood substrate, (c)
treatment of MDF substrate. The photos were taken by Nikon D5600 photo camera (f/6.3, 0.1 s, ISO 1600).
wood-based products in indoor applications [12,13]. However, a pre material are reflected in changes in surface wettability, roughness, color,
requisite for adequate surface protection of wood-based substrates with and gloss [30,31]. Considering only coated surfaces, weathering affects
coatings is good wettability of surfaces with a liquid coating [14]. the mechanical properties of the coating, such as adhesion and hardness
Wettability can be evaluated by a contact angle (CA) measured between [32–35].
a horizontal surface of a solid and the surface of a coating droplet. A The physical and mechanical properties of coated materials are
lower coating CA indicates better and more desirable wettability [15]. influenced by the roles of the coating film, underlying substrate, and the
From the perspective of the substrate, besides the higher polar character interface, which together form the surface system [36]. External in
of the surface free energy (SFE), better wettability is associated with fluences on coated materials are reflected in damage at different levels.
higher surface roughness [15,16]. Deformation responses of the coating film or the entire surface system
It is common practice to machine wooden surfaces before applying can be analyzed on a microscopic level [37].
coatings. Alternatively, the wettability and other surface properties of The present study aims to quantify the possible influence of plasma
any wood-based material can be modified by the use of plasmas in air or pre-treatment on the properties of MDF coated with a waterborne
other gasses, which can be done at atmospheric or reduced pressures coating and on the performance during a subsequent exposure to AAW.
[17]. In particular, as reported in the literature, dielectric barrier Pre-treatment of the MDF substrate was performed using a recently
discharge (DBD) plasmas are most commonly used for the treatment of developed DBD plasma in a floating electrode configuration generated in
MDF. For instance, Wolkenhauer and co-workers [18] reported air at atmospheric pressure. The influence of PT was first investigated in
increased hydrophilicity of plasma-treated (PT) MDF. This was the terms of surface morphology and wettability of MDF with water and
reason for enhanced adhesion performance of PT MDF with waterborne coating. The performance of the coated MDF samples, both untreated
polyvinyl acetate adhesive. In a recent study, Hazir and co-workers [19] and PT, was evaluated during 250 h of AAW in interior mode in terms of
reported up to 22% improvement in adhesion strength of coating system color, gloss, chemical properties, wettability with water, microstructure,
composing of waterborne coatings on plasma pre-treated MDF. Appli and morphology. Finally, the influences of PT and AAW on the me
cations of other types of plasmas on MDF were also investigated. The chanical properties of the coated MDF were determined by analyzing the
main process parameters when using a plasma torch to modify MDF response of the surfaces to scratching and by measuring the peel force of
surfaces were investigated by Perisse and co-authors [20]. De Cade the coating films.
martori and co-workers [21] reported an increased oxygen content on
MDF surfaces and their improved wettability after helium-DBD treat 2. Materials and methods
ment. In another study, improved adhesion of acrylic coating was found
when argon was used as a working gas [22]. MDF was also used as a 2.1. Materials
substrate for the deposition of a macroscopic coating layer of polyester
with a plasma jet [23]. From 3 mm thick MDF boards, specimens with dimensions of 300
Exposure of uncoated or coated wood-based materials to weathering, mm × 75 mm were divided in untreated (UT) and plasma-treated (PTd)
including light irradiation, elevated relative humidity (RH), and tem series. Prior to experiments, the material was stored in a chamber with a
perature [24], results in various changes in the properties of the bulk temperature of 20 ◦ C and RH of 65%. Under these conditions, the MDF
material [1] or its surface [25–27]. Long-term natural weathering can be reached a density of (802 ± 10) kg/m3 and an equilibrium moisture
substituted with accelerated artificial weathering (AAW [28]). Through content of 10.4%, as determined gravimetrically.
the exposure of a particular material to AAW, the performance of the As a coating material, a pigmented commercial acrylic waterborne
material can be evaluated much more quickly. In an AAW chamber, coating (Belinka Interier, Belinka Belles, d.o.o., Ljubljana, Slovenia)
environmental conditions are controlled according to defined test pro with a solid content of 37.8% was used.
tocols. Irradiation of natural sunlight to tested material can be imitated
with a xenon-arc lamp [29].
Combinations of structural and chemical changes in the irradiated
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J. Žigon et al. Materials Chemistry and Physics 263 (2021) 124358
2.2. Plasma treatment process 2.6. Accelerated artificial weathering (AAW) process
MDF samples were treated with non–thermal DBD plasma in floating The coated MDF samples, either UT, PTd-2 or PTd-3, were cut in two
electrode configuration (FE-DBD) in air at atmospheric pressure. The halves and exposed to AAW in the Atlas SUNTEST XXL + chamber (Atlas
details of the setup are described in previous studies [38,39]. Alter Material Testing Technology, Mount Prospect, IL, USA) according to the
nating high voltage (frequency 5 kHz, 15 kV peak voltage) was supplied EN ISO 11341 [45] standard in the interior mode. The xenon-arc lamp
by high voltage power source into two parallel brass electrodes, each behind a 3 mm glass filter produced a light spectrum equivalent to
insulated by an alumina ceramic dielectric. The distance between the sunlight entering through the window glass [28,46]. Settings of the
insulated electrodes was set to 5 mm, and the distance between the di AAW device established the following conditions in the chamber: a light
electrics and the surface of the workpiece was 1 mm. Fig. 1 shows the irradiance of 340 nm, irradiation power of 0.35 W m− 2, a RH of 65%, a
sketch of the plasma setup and example photos of the plasma discharges. chamber temperature of 35 ◦ C and the temperature at the black panel
The MDF, or any other lignocellulosic substrate (e.g. wood), represents sensor of 55 ◦ C. The samples were exposed to weathering for 10 h, 50 h,
opposite counter electrode on a floating potential. PT of individual MDF 100 h, and 250 h. As reported in the literature, the selected durations of
workpiece was performed at the samples’ moving rates of 2 mm/s irradiation to xenon-arc light lead to detectable changes in various
(sample series designated PTd-2) and 3 mm/s (sample series designated properties of materials similar to those used in this study [28,30,47].
PTd-3) in a room with a temperature of 20 ◦ C and a RH of 35%. After completion of each weathering interval, three samples from each
series were taken out of the chamber for further work and analyses.
3
J. Žigon et al. Materials Chemistry and Physics 263 (2021) 124358
scanning electron microscope FEI Quanta 250 (FEI, Hillsboro, OR, USA). mm × 100 mm in size was clamped on a turntable. The 90◦ angled
Prior to observations, samples were coated with a gold conductive layer. diamond test tip with the radius at the tip of 90 μm was attached to a
Images were acquired with the backscatter detector at 1000 × magni load arm, which applied the test load to the specimen. After one full
fication in high vacuum (0.085 Pa) with an electron source voltage of rotation of the specimen (30◦ /s), circular traces with diameters of 45
5.0 kV, at a working distance of 10 mm, and a spot size of 3.0 nm. During mm (applied force 5 N) or 55 mm (applied force 7 N) were induced on
the acquisition of each image, the time of beam passage through the the specimen surface (Fig. 2a). Morphological studies of the residual
sample was 60 μs. SEM was also used to determine the dry coating film patterns were performed by CLSM on 5 sections of the individual scratch
thickness and to analyze the scratch traces (Section 2.11). to obtain representative results of the response to scratching on the
wider surface. Generalized 3D scratch maps were created (Fig. 2b), in an
2.11. Determination of response to scratching attempt to model material contact behavior. Similarly to what was re
ported by Barletta and co-authors [11], the 3D reconstruction of the
The response of the coated surfaces to scratching was determined scratch patterns using the profiler enabled the analysis of the deforma
during AAW according to the modified circular method described in EN tion response. As shown in Fig. 2c, the surface area of the scratch and the
15186 [49] with a scratch hardness tester (model 413, Erichsen GmbH & average depth of the scratch were determined. An example of the height
Co. KG, Hemer, Germany) as presented in Fig. 2. The specimen of 100 profile (mean of 5 profiles measured per length of individual scratch
Fig. 3. The principle of coating peeling force determination: (a) schematic representation of removal of the glued cotton strip from the coated MDF sample (di
mensions in mm) and (b) the detected peeling force as a function of the measurement time (red line represents the mean detected force). (For interpretation of the
references to color in this figure legend, the reader is referred to the Web version of this article.)
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J. Žigon et al. Materials Chemistry and Physics 263 (2021) 124358
Table 1
The calculated components of surface free energy on MDF substrate.
MDF substrate Surface free energy components [mJ/m]
where V is the volume of the scratch [μm3], A is the measured area of the
scratch [μm2], l is the length of the analyzed scratch [1275 μm], and d is
the average depth of the scratch [μm].
The top views and cross sections of the scratch traces and their sur
roundings were analyzed with SEM. Images were acquired with the large
field detector at 300 × and 1000 × magnification in low vacuum (50 Pa)
with an electron source voltage of 5.0 kV, at a working distance of 10
mm, and a spot size of 3.0 nm. During the acquisition of the image, the
time of beam passage through the sample was 60 μs.
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J. Žigon et al. Materials Chemistry and Physics 263 (2021) 124358
with xenon light and increased RH in the chamber, the color changes of
the samples slowed down slightly. For all three sample types, the color
changes were visible to the naked eye (ie. ΔE ≥ 1) during the interval
between 100 h and 250 h of AAW. During the whole period of AAW, the
most pronounced color changes were present on the UT samples, less on
PTd-3 and PTd-2 samples. This is again in good agreement with the
results of gloss changes and could be the consequence of the improved
wettability of the MDF surface with the coating and other properties of
the coated MDF [56]. At the end of the AAW, the ΔE* for UT samples
was 1.62, for PTd-3 samples 1.46 and for PTd-2 samples 1.32.
Fig. 6. Color changes of UT, PTd-2 and PTd-3 coated MDF during the time of AAW (left) and the pictures of the samples during the time of AAW (right). (For
interpretation of the references to color in this figure legend, the reader is referred to the Web version of this article.)
6
J. Žigon et al. Materials Chemistry and Physics 263 (2021) 124358
When comparing coated MDF before AAW and after AAW, weath
ering caused changes in the microstructure of the coating film (Fig. 9).
Such structural changes were detected on both UT and PTd samples.
Apparently, the surface microstructure of the unexposed sample was
relatively homogenous. After 250 h of weathering, semi-circular de
formations appeared in the coating film, which were attributed to the
photo-degradation of the coating polymer induced by light transmission
[63]. These physical changes are most likely consistent with chemical
changes detected with ATR-FTIR analysis [51]. However, no blistering
or cracking was detected, which would possibly occur after prolonged
weathering [64].
The roughness of MDF depended on many variables, such as the type
of raw material, the type and amount of resin used, the moisture content
of the boards, the sanding process during manufacture, etc. [65].
Treatment of the MDF substrate with plasma caused a reduction of
surface roughness. On average, the arithmetic mean surface roughness
(Sa) of PTd-2 MDF decreased by 0.17 (±0.06) μm, while Sa of PTd-3 MDF
Fig. 7. ATR-FTIR spectra of coated samples in the wavelength region between decreased by 0.13 (±0.03) μm. This reduced surface roughness of MDF
2750 cm− 1 and 3050 cm− 1, recorded after different intervals of AAW. Bands at after PT could be the consequence of surface cleaning [39], but not
2850 cm− 1 and 2920 cm− 1 are marked. surface etching, as often reported when the PT process was carried out
with other types of setups and by different treatment parameters [66].
The relative changes of Sa of the coated MDF with respect to the pre-
Fig. 9. SEM micrographs of the coated UT MDF surface: (a) non-weathered sample and (b) sample after 250 h of AAW. Black arrows point to deformations in the
coating film, which appeared during weathering. The length of the scale bars is 50 μm.
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J. Žigon et al. Materials Chemistry and Physics 263 (2021) 124358
treatment method and time of AAW are presented in Fig. 10. The results higher elasticity of the coating film. Exposure of coated material to AAW
showed an increase in surface roughness with weathering. This behavior with light irradiation (including ultra-violet light) and elevated tem
had a relevant influence on the decrease of gloss and consequently on perature, appeared to make the coating film harder [2] or more resistant
the appearance of the polymer coating [67]. Scalarone and co-workers to scratching [71]. This is assumed to be due to the shorter deformations
[68] reported that the most relevant morphological changes, which of the coating film and smaller pile-up formations in the scratch sur
occur with time to waterborne acrylic coatings, are primarily related to roundings. As supported by the findings of ATR-FTIR analysis, the
the exudation of surfactants. In addition, the photo degradation of coating polymer became more crosslinked, but more brittle [36,72].
coating during weathering was accompanied by oxidation, hydrolysis Determination of the mechanical properties (e.g. tensile strength) of
and scissions of the polymer chains. This lead to the removal of low non-weathered and weathered free film of the coating might addition
molecular weight compounds, thus generating micro-cavities and ally support this assumption [12,13].
micro-holes on the surface [58]. Pre-treatment of MDF with plasma did The representative 2D cross sectional profiles of the scratch patterns
not seem to have any effect on the changes in surface roughness of the and their surroundings, as obtained by the CLSM investigation and
coating film for the examined time of AAW. The images of the coated UT extracted by 3D morphology, are shown in Fig. 12. The width and depth
and PTd MDF before AAW and after 250 h of AAW, showing the surface of the scratch profile depended on the force applied to the scratch tip.
morphology detected by CLSM, can be found in the supplementary The larger the force, the wider and deeper the scratch becomes.
material (Fig. S2). Morphological 3D images of coated and scratched UT and PTd MDF
before AAW and after 250 h of AAW, are provided in the supplementary
material (Fig. S3).
3.7. Response of surfaces to scratching
From the scratch and morphological data, including scratch area and
average depth of each scratch, the volume of the material scratched out
Exemplary SEM images of the samples’ surfaces after scratching with
was calculated (Fig. 13). As expected, and with a similar trend for the 2D
a tip loaded with a force of 5 N are shown in Fig. 11. The advancing tip
cross sectional profiles of the scratch patterns, the volume scratched out
caused deformations in the entire surface system, i.e. in the coating film
was greater when the surfaces were scratched with greater (7 N) than
and underlying MDF substrate, regardless of the load applied to the tip.
lower (5 N) force. A large dissipation of the calculated volumes indicates
The ploughing phenomenon of flat surfaces caused the appearance of
large differences in the areas and depths of the analyzed scratching
fractures in the form of pile-ups at the scratch pattern surface [69]. The
traces at the selected spots. Although the error bars partially overlap
pile-up formations were the result of the deformation induced in the
between the filled or hatched columns, the trend of decreasing volume
material by the compressive and tensile stress fields that develop in front
with time of AAW was visible. Again, the reason for this behavior can be
of and behind the advancing tip during the progressive scratching load
found in the increasing crosslinking of the coating polymer with time
[70]. For the sample cross section shown in Fig. 11a, the scratch was
and the increased resistance of the coating to mechanical damage [61].
approximately 170.8 μm wide and 46.2 μm deep. The thickness of the
However, an influence of the pre-treatment method of the MDF substrate
coating dry film was measured at different spots of the micrographs as
was again not found.
shown in Fig. 11b, and was estimated to be 37.7 ± 5 μm. No obvious
differences in the coating film thickness were detected on UT MDF and
PTd MDF. Top-view SEM analysis of the scratches revealed the differ 3.8. Coating peeling force
ences in the deformations caused on the non-weathered sample
(Fig. 11c) and on the sample exposed to AAW for 250 h (Fig. 11d). For The scratch resistance of polymer films is generally related to the
the non-weathered sample, the longer deformations of the coating film adhesion strength of the films to the substrate [65,66,73]. The results of
and larger pile-up formations in the scratch surroundings indicated a the coating peeling force measurements did not show a continuous trend
8
J. Žigon et al. Materials Chemistry and Physics 263 (2021) 124358
Fig. 12. Examples of 2D cross sectional profiles extracted from the visualized 3D morphology of the scratches and their surroundings. Depending on the MDF pre-
treatment method, the time of AAW and the force applied by the scratching tip, the figures follow as: (a) UT, 0 h of AAW, 5 N, (b) UT, 250 h of AAW, 7 N, (c) PT, 2
mm/s, 0 h of AAW, 5 N, (d) PT, 2 mm/s, 250 h of AAW, 7 N, (e) PT, 3 mm/s, 0 h of AAW, 5 N, and (f) PT, 3 mm/s, 250 h of AAW, 7 N.
with time of AAW, neither with the pre-treatment method of the MDF
before coating application (Table 2). For the time of AAW used in this
study, the adhesion force of the coating films showed no trend of change,
neither negative nor positive. Pre-treatment of the MDF substrate with
plasma did not increase the adhesion of the waterborne coating to the
substrate, as could be expected from the reports in the literature (e.g. ref.
[18]). Although the PT increased the SFE of the MDF surface, this pos
itive influence did not reflect in the increased coating adhesion strength
determined with peeling force measurements. The reason for this could
be due to the method used. A different result could be obtained by using
a different method for determination of coating adhesion strength (e.g.
by determination of coating pull-off adhesion strength) or by performing
the measurements on more sample replicates. However, the influence of
weathering or pre-treatment of MDF with plasma on coating adherence
to the substrate could be more pronounced with longer exposure to
weathering than used in this study.
4. Conclusions
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Table 2
The results of determination of coating peeling force on UT and PTd coated MDF.
Type of coated MDF Time of AAW [h]
0 10 50 100 250
Fa [N] AFb [%] Fa [N] AFb [%] Fa [N] AFb [%] Fa [N] AFb [%] Fa [N] AFb [%]
UT 11.21 (2.16) 80 10.91 (3.1) 70 17.69 (4.1) 65 16.43 (3.2) 85 13.37 (2.3) 80
PT, 2 mm/s 10.88 (2.09) 75 15.76 (2.3) 75 14.87 (3.7) 70 15.17 (2.0) 55 18.77 (3.0) 80
PT, 3 mm/s 15.64 (3.70) 75 13.62 (2.1) 75 14.21 (3.4) 85 15.14 (3.2) 70 13.85 (2.8) 60
a
–Peeling force, standard deviation shown in parentheses.
b
– Share of coating adhesion failure.
effect on the wettability of MDF with a waterborne commercial acrylic Appendix A. Supplementary data
coating. Both the increased SFE and improved wettability could be
related to the reduced surface roughness and surface oxidation after Supplementary data to this article can be found online at https://doi.
treatment with plasma. Exposure of the coated MDF to an accelerated org/10.1016/j.matchemphys.2021.124358.
artificial weathering (AAW) process resulted in changes in the visual and
mechanical properties of the coating films. Surface gloss decreased with References
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