Wettability characterization and adhesion enhancement of arc-treated surface of aluminum alloys

Abstract

The aim of this study is to determine the wettability-enhancing effects of an atmospheric pressure, direct current (DC) plasma arc discharge on the surface of aluminum alloys. Wettability is a critical factor in engineering applications such as biomedical implants, painting, and adhesive bonding. For example, in the realm of adhesive bonding, greater wettability improves a metal substrate's attraction to an adhesive material and results in a higher bond quality. In this study, the contact angle was determined and compared as a measure of the wettability using two different techniques: the sessile drop and the ballistic deposition with water as a test liquid. The effect of different arc discharge process parameters on the wettability, including arc current and plasma torch velocity, was studied. A two-dimensional finite element analysis based on the volume-of-fluid model was carried out to explore the behavior of droplet (e.g., spreading and stabilization) on an ideal surface. Additionally, the values of the dynamic receding contact angle were measured through the simulation by applying the tilted plate method and considering the surface roughness to compare the results with the values obtained from the ballistic deposition method. Studying the wettability alteration of the surface of aluminum alloys subjected to the arc treatment revealed the wettability reduction over time. Additionally, it was found that there was a linear correlation between the contact angle value and the strength of adhesively bonded joints using two structural adhesives. The results of this study in the wettability modification of aluminum subjected to the arc treatment and wettability alteration of the treated substrate over time may be used as a quality assurance tool to design the production process and achieve the desired quality and strength in adhesively bonded joints.