Surface Topography and Functional Implications of Dry Physical Surface Treatments on UHMWPE

Ultra–high molecular weight polyethylene (UHMWPE) is a key material for high–performance fibers produced via gel–spinning, owing to its extremely high molecular weight, tensile strength, and chemical stability. However, its intrinsically low surface energy and chemical inertness severely limit wettability and interfacial bonding with surrounding matrices, restricting the effective translation of its molecular advantages into macroscopic performance. To address this challenge, this review critically examines surface treatment strategies developed to overcome the surface limitations of UHMWPE, with particular emphasis on comparing wet chemical and dry physical modification routes. While wet chemical methods are briefly discussed for context, the primary focus is placed on dry physical surface treatments, including plasma treatment, and electron–/γ–beam irradiation. The fundamental principles, activation mechanisms, and process–structure–property relationships governing these approaches are systematically analyzed. Through mechanistic interpretation and representative case studies, the cause–and–effect relationships between processing parameters and changes in surface chemistry, surface energy, morphology, and fiber cohesion are elucidated. Special attention is given to surface treatments that enhance interfacial adhesion and mechanical performance while preserving the bulk chemical structure, molecular orientation, and intrinsic mechanical integrity of UHMWPE, providing a framework for designing durable, high–performance UHMWPE fibers and composites.