Chemical Surface Treatment for Enhanced Bonding Strength between Polymer Coating and Aluminum Alloy

Polymer materials are sometimes molded to aluminum alloy to form integrated industrial parts for special applications, such as high strength, heavy duty applications. To ensure the bonding strength for long term applications, chemical treatment of aluminum surface is a quick and efficient method prior to polymer injection molding onto aluminum part. In this study, chemical etching and anodizing processes were studied to obtain suitable surface roughness and porous structures to enhance the penetration of polymer into the pores leading to interfacial anchoring and high bonding strength. Surface roughness, surface contact angles, and surface porous structures were investigated by surface Profilometer, contact angle tester, and scanning electron microscopy. Bending tests and cracking analyses were carried out to determine the bonding strength. Optimized chemical treatment recipe and process parameters were established. Preferred surface characteristics are defined. The failure mechanism of bending test was analysed and correlated to the bending fracture phenomina.