Effects of surface microstructure and molding parameters on injection bonding strength of polyphenylenesulphide-aluminum alloy

Abstract

The direct injection molding process of PPS-aluminum alloy composite parts under vacuum condition was conducted and the processing parameters were optimized through the numerical simulation and orthogonal test design. The effect of surface microstructure of the aluminum alloy splines and injection molding processing parameters on the bonding strength of the composite parts were discussed. The results show that the bonding strength of the composite parts increases with not only the increase in the diameter and quantity of the microscopic pores and also the surface roughness of the aluminum alloy splines. The bonding strength can also been improved under a higher vacuum. The bonding strength is highly correlated to the micromechanical interlocking structure formed by the PPS embedding into the rough surface of the aluminum alloy splines.