Bonding strength enhancement of a 30-wt.% GF/PET–2024 aluminium alloy joint by synergistic action of multi-scale mechanical interlocking and multiplex H-bonding

Abstract

In this study, micro-scale cellular and nano-scale labyrinth structures were obtained on the surface of A2024 aluminium alloy adherends through ultrasonic-aided corrosion using an FeCl3 etchant solution to significantly enhance the mechanical interlock of it and a 30-wt.% glass-fibre-enhanced polyethylene terephthalate substrate. The tensile shear strength of the 30-wt.% GF/PET–A2024 joint was increased to 31.84 MPa. The subsequent treatment of an appropriate amount of KH-892/PVA transformed the surface of the aluminium alloy from hydrophobic to hydrophilic to significantly improve its wettability. Furthermore, this treatment generated multiplex hydrogen bonding of O–H⋯O⋯H–N at the interface, further improving the tensile shear strength of the joint up to 50.94 MPa, which is significantly higher than the values obtained using exiting methods. The tensile shear tests of a ring-shaped insulator specimen according to GB 7251-87 verified the improved fracture work equation herein and the bonding strength enhancement of the 30-wt.% GF/PET–A2024 aluminium alloy joint treated by ultrasonic-aided corrosion with an FeCl3 etchant solution and pre-coating of an appropriate amount of KH-892/PVA.