Drying an acrylate formulation on carbon and stainless steel coupons leads to films with dramatic differences in tack. The tack of the film deposited on stainless steel is high, as expected, but that of the film on carbon steel is much lower. This difference arises from changes in the polar component of the surface energy. Atomic force microscopy showed that the carbon steel-based film had a rougher surface, and that the components separated into the valleys in the surface, thereby reducing the overall tack. The origin of the phenomenon lies in the nonuniformity of carbon steel. Local differences in heat transfer from the metal to the adjoining liquid layer gives rise to temperature differences at the surface of the film as it dries. This induces Marangoni flow, which leads to inhomogeneities in the composition and topology of the surface. (c) 2006 American Institute of Chemical Engineers