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Materials Chemistry and Physics 263 (2021) 124358

Contents lists available at ScienceDirect

Materials Chemistry and Physics


journal homepage: www.elsevier.com/locate/matchemphys

Surface properties of coated MDF pre-treated with atmospheric plasma and


the influence of artificial weathering
Jure Žigon *, Matjaž Pavlič , Marko Petrič , Sebastian Dahle
University of Ljubljana, Biotechnical Faculty, Department of Wood Science and Technology, Jamnikarjeva Ulica 101, 1000, Ljubljana, Slovenia

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.

1. Introduction objective of surface treatments with coatings. With the application of


varnishes, stains and paints it is also possible to improve the appearance
Medium density fiberboard (MDF) is a widely used wood-based and extend service life of MDF [6,8]. Waterborne coating systems
engineered composite material for construction and furniture [1,2]. represent a promising alternative for the surface treatment of MDF [9].
Physical and mechanical properties, easy workability, and ready avail­ The selection of a particular coating depends on the environmental
ability make MDF favorable for the production of interior fittings, office conditions [10]. Coatings for interior use have to withstand different
furniture, or kitchen cabinets [3,4]. The smoothness, non-porosity, and degradation factors due to the daily activities in our living spaces. The
homogeneity of the MDF surface also enables application of different response of the coated product to light irradiation, climatic variations,
types of coating materials [5–7]. mechanical damage (scratching, abrasion, impacts) and chemical dam­
Apart from providing a specific visual characteristics of all wood- age [2,8] are of prime importance in indoor areas [8,11,12]. Poly­
based materials, protection against degradation due to the weathering acrylates and polyurethanes are considered the most important binders
process, including physical and chemical influences, is the main in the formulation of transparent, waterborne coating materials for

Abbreviations: MDF, Medium density fiberboard; AAW, Accelerated artificial weathering.


* Corresponding author.
E-mail addresses: jure.zigon@bf.uni-lj.si (J. Žigon), matjaz.pavlic@bf.uni-lj.si (M. Pavlič), marko.petric@bf.uni-lj.si (M. Petrič), sebastian.dahle@bf.uni-lj.si
(S. Dahle).

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.

2.3. Surface roughness measurements


2.7. Determination of visual properties

The influence of PT on the surface morphology of MDF was examined


The changes in visual properties, gloss, and color of the surfaces of
with a LEXT OLS5000 confocal laser scanning microscope (CLSM,
the samples were monitored during the AAW intervals in 10 measure­
Olympus, Tokyo, Japan). Morphology analysis was performed on 5 spots
ments of each property on each sample. Gloss, as a property related to
of MDF surfaces before and after PT (PTd-2 and PTd-3, 3 samples each),
the intensity of light reflected in the specular direction [8], was
as well as during AAW (c.f. Section 2.6), and for analyzing the scratching
measured with a gloss meter AcuGloss TRI (X-Rite, Grand Rapids, MI,
traces (c.f. Section 2.11). To ensure repeatability, the measurements
USA) at the angle between the light source and the observed plane of
were recorded each time at the same spots of each individual sample at 5
60◦ . CIELAB color space components (L*, a* and b*) were measured
– fold magnification with the scanned area of 2560 μm × 2560 μm. Non-
using the spectrophotometer SP62 (X-Rite) with the D65 light type.
contact 3-dimensional (3D) laser microscopy was performed using a
Color changes of the sample surfaces (ΔE*) were calculated according to
laser light source with a wavelength of 405 nm, with a maximum lateral
equation (1):
resolution of 0.12 μm. The OLS50-S-AA software (Olympus, Tokyo,
[ ]
Japan) was used to calculate the average absolute deviation of the ΔE* = √ (ΔL* )2 + (Δa* )2 + (Δb* )2 , (1)
roughness irregularities from the mean sample surface over the sam­
pling area Sa [40]. where the parameters ΔL*, Δa* and Δb* represent the changes between
the initial value of L*, a* and b* and the value of L*, a* and b* at the end
of each AAW interval.
2.4. Determination of surface free energy (SFE) and wettability with
coating
2.8. Attenuated total reflection Fourier transform infrared (ATR-FTIR)
spectroscopy
Surface wetting properties and surface free energies on UT and PTd
MDF were determined on the basis of contact angle (CA) measurements
Forsthuber and Grüll [45] reported the usability of ATR-FTIR to
of three liquids: deionized water (surface tension: polar part γP = 51.0
quantify the photo oxidation rates of coatings due to the exposure to
mN/m, dispersive part γD = 21.9 mN/m), diiodomethane (γP = 0.0 mN/
xenon-arc light. In this study, ATR-FTIR was used to evaluate the
m, γ D = 50.8 mN/m) and formamide (γP = 39.0 mN/m, γ D = 19.0 mN/m)
changes in chemical bonds in the coating films due to photochemical
[34]. Twelve 5 μL droplets of each liquid were applied to 3 (100 mm ×
degradation during AAW. The spectra were recorded using the Perki­
75 mm) samples of the UT series and each PTd series with Theta optical
nElmer Spectrum Two (PerkinElmer Inc., Waltham, MA, USA) ATR-FTIR
goniometer (Biolin Scientific Oy, Espoo, Finland). The corresponding
spectrometer, with a LiTaO3 detector type in the transmittance mode.
goniometer software was used to measure the CA between the surface of
Spectra were corrected for background and measured in 3 spots (16
the substrates and the tangent line fitting the shape of droplet. The SFE
scans per spot) on individual sample, in a wavelength region from 600
was calculated using the Lifshitz-van der Waals acid-base method
cm− 1 to 4000 cm− 1 at a resolution of 0.5 cm− 1. Relevant absorption
[41–44]. The same procedure was used to measure the CA of the coating
bands were then interpreted using the corresponding software (Spec­
on 3 MDF samples per series, where the volume of the applied droplets
trum V.10.5.3, PerkinElmer Inc.).
was 10 μL. After 24 h, the top-view photos of cured coating droplets
were taken using photo camera (f/5.6, 0.02 s, ISO 1250) and the areas of
2.9. Wettability of coated samples with water during AAW
the droplets were measured using Fiji software (ImageJ 1.46d, Madison,
WI, USA).
In order to detect the influence of AAW on the in hydrophobic
characteristics of the coating film, the CAs of deionized water were
2.5. Coating film formation measured after each weathering period. Optical goniometer Theta was
used to measure the angle of 10 5 μL water droplets deposited on the
The UT and PTd MDF samples (5 per series) with the initial di­ surface of each sample of coated MDF. The lower the CA was, the lower
mensions were manually coated using a quadruple coating applicator. the ability of a coating film to protect the surface from water [48].
At the rate of applicator movement of approximately 30 mm/s, coating
films with a wet film thickness of 240 μm (approximately 130 g/m2) 2.10. Scanning electron microscopy (SEM) analysis
were created. The determination of the dry film thickness is explained in
Section 2.10. Before further analyses, the samples were stored for 21 SEM was used to analyze the microscopic changes on the sample
days in a dark room at a temperature of 20 ◦ C and a RH of 35%. surfaces due to AAW. The spots of interest were observed with a

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J. Žigon et al. Materials Chemistry and Physics 263 (2021) 124358

Fig. 2. Methodology of determination of the sur­


face response to scratching. (a) Schematic repre­
sentation of the deformations in a coating film and
MDF substrate (marked area) caused by the loaded
advancing tip. (b) Morphological picture of the
sample surface with the scratch trace, obtained with
CLSM. The arrows are pointing the pile-up forma­
tions at the border of the scratch. The dimensions of
the analyzed spot are 2560 μm × 2560 μm. (c) Top
view of the scratched sample surface, obtained with
CLSM. The length of the scale bar is 0.5 mm. The
area of the scratch is marked. 5 height profiles were
measured, as shown by the vertical line in the
middle of the picture. (d) The height profile ob­
tained along the analyzed distance, obtained with
CLSM. The marked » V « shape area, defined by the
area (A) and depth (d), represents the cross section
of the calculated scratch volume.

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]

γLW γAB γ+ γ– γtot

UT 34.9 0.3 3.2 0.0 35.2


PT, 2 mm/s 44.1 9.1 1.6 12.7 53.2
PT, 3 mm/s 42.0 7.3 1.4 9.2 49.3

section) obtained perpendicular to the scratch is shown in Fig. 2d. The


volume of the caused scratch trace was evaluated as follows:
A×l×d
V= , (2)
2

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.

2.12. Determination of coating peeling force


Fig. 4. Evolution of coating CAs applied to different MDF substrates and areas
The peeling force test was applied to determine the adhesion of the of cured coating droplets. The top row of images shows the corresponding side-
coating to UT and PTd MDF samples with respect to time of AAW. The view photos of the droplets 1 s after deposition. The bottom row of images
shows the top-view photos of the droplets 24 h after deposition. The length of
200 mm × 20 mm cotton tissue strips were glued on the coated MDF
the yellow scale bars is 2 mm. (For interpretation of the references to color in
samples with a 2-component epoxy glue (UHU plus endfest, UHU, Bühl,
this figure legend, the reader is referred to the Web version of this article.)
Germany). After 24 h, the boundaries of the glued strips were carefully
cut down to the substrate to prevent propagation of defects outside of
this assumption was not part of this study.
the test area. The bonded cotton strips were peeled using a Z100 tensile
testing machine (Zwick GmbH & Co. KG, Ulm, Germany) as presented in
Fig. 3. The strips were pulled at a peel angle of 15◦ at a testing machine 3.2. Coating CAs
crosshead speed of 100 mm/min. The recording of the peeling force
started when it firstly exceeded 10 N. From this point on, the force was Fig. 4 shows the evolution of the coating CAs on UT, PTd-2, and PTd-
recorded every 0.01 s of measurement. After the test, the share of the 3 MDF substrates as well as the areas of the cured coating droplets 24 h
coating adhesion failure was visually estimated. The reported peeling after deposition. The initial CAs decreased rapidly on all three samples
force and percentage of adhesion failure represent the average of 3 in the first 10 s after droplet deposition due to penetration of the liquid
measurements for each type of a sample. into the substrate and due to the spreading of the liquid over the surface
of the solid [50,51]. The increase in SFE of MDF after PT contributed to
3. Results and discussion improved surface wettability of MDF with a waterborne acrylic coating.
As presented in Fig. 4, the formed CAs of coating droplets were signifi­
3.1. Surface free energy cantly lower when applied to PTd MDF than to UT MDF. However, the
difference in coating CAs observed on PTd-2 and PTd-3 samples after 60
PT of MDF caused an increase of both the non-polar dispersive s of measurement of 39.6◦ and 40.1◦ , respectively, is only minor and
Lifshitz-van der Waals (γLW) and polar acid-base (γ AB) components of does not reflect the larger difference in SFE between PTd-2 and PTd-3.
SFE, as shown in Table 1. Compared with UT MDF, the γ LW of PTd MDF Perisse and co-authors [19] found that the longer PT applies more en­
was found to be about 1.2-times higher for both PTd-2 and PTd-3. ergy to the MDF surface and therefore a greater decrease in CAs is
However, PT of MDF significantly increased γ AB: 30.3-times for PTd-2 achieved than with a faster treatment. The reason for this is due to
and 24.3-times for PTd-3, compared to the γ AB values of UT MDF. It surface oxidation, including the formation of C–O, C– – O and O–C– –O
was also shown that PT decreased the electron-donating part of γAB (γ− ) bonds.
but greatly increased the γAB electron-accepting (γ+) part. Finally, as The lower CAs of the coating are reflected in a larger area of MDF
calculated according to Lifshitz-van der Waals acid-base method, the covered by the droplets. 24 h after deposition, the droplets on UT
total SFE (γtot) of MDF was the lowest on UT samples (32.5 mJ/m), samples covered in average 16.9 mm2 of MDF, on PTd-2 samples 23.9
higher on PTd-3 samples (49.3 mJ/m), and the highest on PTd-2 samples mm2, and on PTd-3 samples 21.5 mm2.
(53.2 mJ/m). These results indicate that MDF was likely oxidized and
thus activated and was significantly more hydrophilic after PT. The 3.3. Changes of color and gloss
lower feed speed of the MDF workpiece through the plasma discharge
increased the SFE of MDF more than higher feed speed. According to the measured gloss values, detected at 60◦ angle of
The improvement of hydrophilicity of MDF by PT is most likely incidence, the analyzed surfaces were denoted as matt glossy [52]. A
influenced by the dielectric properties of MDF. Higher moisture content reduction of gloss with time of AAW was related to the degradation of
in the treated substrate makes MDF more electrically conductive, which the coating during weathering [27,53] and the associated increased
also affects the effect of PT to enhanced hydrophilicity [4]. However, surface roughness of a coating [54,55]. Similar to what was reported by

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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.

3.4. ATR-FTIR spectra

ATR-FTIR experiments were performed in order to study the chem­


ical degradation of the coating acrylic systems caused by the AAW. As
shown in Fig. 7, the only and constantly noticeable spectral changes
were detected in a broad band between 2800 cm− 1 and 3000 cm− 1, in
the alkyl region [57–60], with the bands at 2850 cm− 1 and 2920 cm− 1
Fig. 5. Changes of gloss of UT, PTd-2 and PTd-3 coated MDF during the time denoting stretching in methyl and methylene groups, including hydro­
of AAW. carbon (C–H) chains [30,61]. The transmittance signal of these bands
became remarkably larger after 50 h of AAW, indicating the formation
Custódio and Eusébio [27], the largest changes in gloss of wood coated of hydroxyl bonds during the degradation of the acrylic resin [45,46].
with waterborne acrylic coating and exposed to AAW were detected at However, no additional changes were detected in the spectra during
the beginning of weathering (Fig. 5). The highest initial gloss was further weathering process. Regardless of the feed speed, the PT had no
detected on PTd-2 samples (16.2), followed by PTd-3 samples (14.5), effect on the detected spectra throughout the spectral entire wavelength
and on UT samples (12.0). The initial gloss values indicated that PT span, which dataset is provided in the supplementary material (Fig. S1).
contributed to the increase in gloss. This could be related to enhanced Chemical degradation of the polymer matrix involves the formation
wettability of the MDF by the coating, but definitely with the reduced of species that are readily ablated from the surface, leading to loss of
roughness of the coating film surface. With the exposure of samples to gloss, increase in hardness, and rougher morphology [52].
AAW the gloss decreased. The greatest decrease in gloss was detected
after the first 10 h of weathering and was very similar for all three
sample types. With further weathering, the gloss decreased at a slower 3.5. Wettability of coated MDF
rate. After 250 h of weathering, the gloss of PTd samples remained
higher than that of UT samples. The gloss of PTd-2 samples decreased to The behavior of water droplets deposited on coated MDF over the
15.2 (− 6.5%), of PTd-3 samples to 13.6 (− 6.2%) and of UT samples to time of AAW was a good indicator of the ability of the coating film to
11.1 (− 7.1%). In conclusion, PT seems to reduce the influence of AAW protect the substrate from water ingress. During the first 50 h of
on the gloss changes. weathering, the initial low wetting character of the coating film seemed
Fig. 6 shows the color changes of UT, PTd-2 and PTd-3 coated MDF to be unaffected. Additional 50 h of AAW caused a slight decrease in the
during the period of AAW. At the beginning of AAW, the dynamics of formed CAs of water droplets. After 250 h of weathering, the wettability
color changes was well related with the gloss changes. As indicated by of the coating film with water increased significantly (Fig. 8). With
the calculated values of ΔE*, the color changes of the coating films were further AAW, an additional loss of coating film wettability would be
the fastest during the first 10 h of weathering. During further irradiation expected [62]. However, the influence of PT on coating films wettability
character was not detected during the entire period of AAW.

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.)

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J. Žigon et al. Materials Chemistry and Physics 263 (2021) 124358

3.6. Changes in coating films microstructure and surface morphology

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. 8. Initial (2 s after deposition) water CAs detected on differently pre-


treated, coated samples as measured after different intervals of AAW.
Fig. 10. Relative changes of surface roughness of coated MDF after particular
interval of AAW.

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

Fig. 11. SEM analysis of scratching traces and the


surrounding on coated MDF, induced by a scratch
tip loaded with 5 N. The length of the scale bars is
50 μm. The top images show the obtained cross
sections of the non-weathered samples: (a) Black
arrows point the boundary of the scratch. The
formed pile-up of out-scratched coating and sub­
strate material is encircled by red dashed line. (b)
The black arrows point to the interface between the
MDF substrate (bottom) and coating film (above).
Here the thickness of the coating dry film can be
estimated. The bottom images show the top-views
of the scratched surfaces: (c) non-weathered sam­
ple and (d) the sample after 250 of AAW. In both
images the red dashed arrows show the direction of
the advancing tip causing scratching traces and the
revealed MDF substrate. Black arrows point to the
deformed coating film in the scratches’ surround­
ing. The formed pile-ups are encircled with a red
dashed line. (For interpretation of the references to
color in this figure legend, the reader is referred to
the Web version of this article.)

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

A non-thermal DBD plasma in a floating electrode configuration (FE-


Fig. 13. Calculated volumes of scratched traces on coated UT and PTd MDF DBD) was shown to be a viable technique for modifying the surface of
samples, with respect to the applied scratching force (5 N – filled columns, 7 N – medium density fiberboards (MDF). The treatment with plasma
hatched columns) and the time of AAW. increased the surface free energy (SFE) of MDF, which had a positive

9
J. Žigon et al. Materials Chemistry and Physics 263 (2021) 124358

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
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