Unraveling a Molecular Adhesion Mechanism at Complex Polymer–Metal Interfaces

Controlling polymer-metal adhesion is critical in ensuring that materials can be cleanly separated during production processes without residue, which is crucial for various industrial applications. Accurately characterizing adhesion on industrial-grade surfaces is complex due to factors like surface roughness and actual contact area between surfaces and the polymer. In this study, we quantified the adhesive behavior of stainless-steel samples with varying surface treatments against a polymer using the surface forces apparatus (SFA) in reflection geometry, as well as X-ray photoelectron spectroscopy (XPS). We compared adhesive properties with the penetration depth of oxygen and the hydroxide-to-oxide ratio, which were modified by plasma and thermal treatments. Our results indicate that both treatment types enhance the deadhesive properties of the materials compared to native passive films, due to decreasing hydroxide functionality on the surface. Thermal treatment reduces adhesion further, due to an even lower hydroxide content, which reduces hydrogen bonding between the surface and polymer. Furthermore, we show that van der Waals forces, which depend on the density, have marginal to no influence on the adhesive behavior. This study not only advances our understanding of the factors influencing polymer-metal adhesion but also demonstrates the application of the SFA in reflection geometry for characterizing industrially relevant rough surfaces.