This study demonstrates effective resistance welding between 7075 aluminum (Al) alloy and carbon fiber/polyether ether ketone (CF/PEEK) composites by combining chemical etching and silanization surface treatments with a polyetherimide (PEI) thermoplastic layer. The effects of this hybrid treatment on the bonding at the 7075 Al alloy/PEI thermoplastic layer interface and the mechanical performance of the welded joints are systematically investigated. Chemical etching created a micro-nano rough surface that enhanced mechanical interlocking and increased hydroxyl group content from 12.7 mol% to 28.5 mol%. Subsequent silanization grafted amino ( NH 2 ) groups onto the 7075 Al alloy surface, enabling hydrogen bonding with the PEI thermoplastic layer. Under the synergistic effects of mechanical interlocking and hydrogen bonding, interfacial bonding is significantly enhanced, increasing the lap shear strength (LSS) of the joint from 0.2 to 24.6 MPa. The fracture failure mode of the welded joint changes from the interfacial failure of the 7075 Al alloy and PEI thermoplastic layer to the interlaminar failure of carbon fiber tearing in the heating element. Summary A new approach enables effective resistance welding of 7075 Al alloy and CF/PEEK composites. A hybrid surface treatment enhances 7075 Al alloy bonding with PEI thermoplastic layer. The hybrid surface treatment induces mechanical interlocking and hydrogen bonding effects. The synergistic effects can significantly enhance the performance of welded joints.
Plastic-Metal hybrids have gained significant attention in automotive and aerospace fields. In the study, the silane was introduced on the surface of anodized micro-nano porous aluminum alloy (Al) plate. The silanized Al sample was then joined with polybutylene terephthalate (PBT) specimen by ultrasonic-assisted hot pressing technology to manufacture hybrid. The interfacial physical embedding structure plays an important role in plastic-metal joining and the scanning electron microscope (SEM) results demonstrated that effective mechanical interlocking was achieved between PBT and Al. X-ray Photoelectron Spectroscopy (XPS) results demonstrated the new chemical bonds occurred at the PBT-Al interface, which acted as bridges in the PBT-Al interface joining. Due to synergistic effect of physical embedding and chemical bonding, the maximum adhesion strength reached 36.3 MPa when the silane concentration was 4 %, which was 37 % higher than that without silane treatment. When the silane concentration exceeds 4 %, leading to blocking pores on the anodized aluminum alloy surface, resulting in a decrease in adhesion strength. In conclusion, these results can provide some ideas and help for the development of subsequent plastic-metal hybrids and practical applications.
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