Abstract
Metal-polymer direct joining is an extremely essential technology because several metal parts, especially those used in automobiles, are currently replaced by polymers to save on weight. This work achieves a strong and direct method for joining aluminum alloy and polybutylene terephthalate through metal surface roughening using abrasive micro-blasting and insert molding. A considerably higher blasting pressure than the usual shot peening enables direct joining without metal preheating. The number of pores with a certain aspect ratio produced on the metal surface has strong correlation with the joining strength due to their mechanical interlocking. Optimized blasting and molding conditions are also obtained to yield high joint strengths.
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