Improved the reliability of nylon 66/ Ti-6Al-4V hot-pressed hybrid by micro arc oxidation voltage-induced porous ceramic structure

Plastic-metal hybrid (PMH) provides a new direction for aerospace and automotive rail transit fields to achieve lightweight. Hot pressing has broad application prospects in plastic/metal hybrids. Before the realization of TC4(Ti-6Al-4V)/PA66(Nylon 66) hybrid by hot pressing, different porous microstructures were prepared on the surface of TC4 by controlling the micro-arc oxidation (MAO) voltage (220 V, 240 V, 260 V, 280 V). Effect of different porous ceramic structures on the hybrid interface. Research shows that the microscopic porous ceramic structure on the surface of TC4 can enhance the surface wettability and wear resistance of TC4. Promote the embedding of PA66 into the TC4 surface to achieve mechanical interlocking. Different microstructures have different effects on bonding strength and failure modes. Especially at 240 V, the interface maximum bonding strength is 11.56 Mpa, and the interface failure mode is a mixed failure caused by plastic cohesion failure and plastic pull-out. In addition, XPS detection generates new chemical bonds, such as Ti-O and -C-Ti-O, at the hybrid interface. Compound reinforcement of mechanical interlocking and chemical bonding is achieved at the interface. In conclusion, these results are crucial for further designing and optimizing plastic-metal hybrids prepared using micro-arc oxidation.