Metal-polymer Hybrid Research Articles

Preparation of glass fiber-reinforced polyphenylene sulfide/magnesium hybrid based on micro-arc oxidation by hot pressing molding

ABSTRACT The construction of surface structures and joining technology has become a key technology for the preparation of polymer-metal hybrid(PMH) materials in recent years. The magnesium alloy surface was subjected to micro-arc oxidation(MAO) to create a micro-nanopore structure, and the Glass fiber-reinforced polyphenylene sulfide/magnesium alloy(GFRPPS/Mg) hybrid joints were prepared by hot pressing molding. The joining mechanism of the GFRPPS/Mg hybrid joints was explored, and the interfacial disruption forms, crystalline properties, embedding depths, and interfacial chemistry of the GFRPPS/Mg hybrids were investigated at different hot pressing temperatures. The results demonstrate that the mechanical strength of the GFRPPS/Mg hybrid joints is a consequence of the interplay between micromechanical interlocking and chemical bonding, and the optimal tensile shear strength is 18.51 MPa. The tensile shear failure of the hybrids can be attributed to a combination of cohesive and interfacial failure. The crystalline properties of the failed surface of GFRPPS were also analyzed by X-ray diffraction (XRD), which revealed that the crystallinity also affects the mechanical properties of the GFRPPS/Mg hybrid joints.

Engineering a superamphiphilic surface for enhanced interfacial bonding in metal-polymer hybrid structure

Insufficient wetting of polymer due to its poor compatibility with metals leads to non-intimate interfacial mutual contact during the thermal-direct bonding process, thus hindering the establishment of effective mechanical interlocking and substantial chemical bonding at the interface, resulting in deficient performance of metal-polymer hybrid structures. To achieve high-quality bonding between non-polar ultra-high molecular weight polyethylene (UHMWPE) and Ti6Al4V titanium alloy (TC4) for the application of artificial joint prostheses, this study innovatively engineered a superamphiphilic (simultaneously superhydrophilic and superlipophilic) TC4 surface, which was achieved through a morphology-chemistry dual regulation strategy. This pretreatment strategy aimed at improving the interfacial compatibility between in-situ oxidized UHMWPE and TC4 and ensuring intimate contact between these two materials during thermal-direct bonding, thus facilitating chemical reactions and mechanical interlocking at the interface. Defect-free and ultra-high-performance TC4-UHMWPE hybrid joints were successfully obtained via friction spot joining (FSpJ) with the lap shear strength reaching 18.05 MPa (higher than all those similar hybrid joints reported in existing literature) and the fracture was confined to the UHMWPE matrix, effectively avoiding interfacial failure. The formation of chemical bonds in the form of COTi at TC4/UHMWPE interface was solidly confirmed based on X-ray photoelectron spectroscopy (XPS) and time-of-flight secondary ion mass spectrometry (ToF-SIMS) analyses. This research presents a compelling strategy for improving interfacial compatibility between polymer and metal for thermal-direct bonding, to overcome the general difficulties in achieving effective interfacial bonding between these two categories of materials with significantly different physiochemical properties.

Multi-Objectives Optimization of Plastic Injection Molding Process Parameters Based on Numerical DNN-GA-MCS Strategy.

An intelligent optimization technique has been presented to enhance the multiple structural performance of PA6-20CF carbon fiber-reinforced polymer (CFRP) plastic injection molding (PIM) products. This approach integrates a deep neural network (DNN), Non-dominated Sorting Genetic Algorithm II (NSGA-II), and Monte Carlo simulation (MCS), collectively referred to as the DNN-GA-MCS strategy. The main objective is to ascertain complex process parameters while elucidating the intrinsic relationships between processing methods and material properties. To realize this, a numerical study on the PIM structural performance of an automotive front engine hood panel was conducted, considering fiber orientation tensor (FOT), warpage, and equivalent plastic strain (PEEQ). The mold temperature, melt temperature, packing pressure, packing time, injection time, cooling temperature, and cooling time were employed as design variables. Subsequently, multiple objective optimizations of the molding process parameters were employed by GA. The utilization of Z-score normalization metrics provided a robust framework for evaluating the comprehensive objective function. The numerical target response in PIM is extremely intricate, but the stability offered by the DNN-GA-MCS strategy ensures precision for accurate results. The enhancement effect of global and local multi-objectives on the molded polymer-metal hybrid (PMH) front hood panel was verified, and the numerical results showed that this strategy can quickly and accurately select the optimal process parameter settings. Compared with the training set mean value, the objectives were increased by 8.63%, 6.61%, and 9.75%, respectively. Compared to the full AA 5083 hood panel scenario, our design reduces weight by 16.67%, and achievements of 92.54%, 93.75%, and 106.85% were obtained in lateral, longitudinal, and torsional strain energy, respectively. In summary, our proposed methodology demonstrates considerable potential in improving the, highlighting its significant impact on the optimization of structural performance.

Achieving a High‐Strength Bonding between Aluminum Alloys and Polymer Composites via Self‐Riveting Welding

Great challenges exist in producing reliable welding between metals and polymer composites. In this study, self‐riveting welding (SRW) is employed to obtain metal–polymer hybrid joints with high load‐bearing capability. In this investigation, it is shown that the SRW joints with a prefabricated hole of 5.8 mm in diameter are characterized by fewer void defects with sufficient polymer filling, a tightly bonded joint interface, and a relatively uniform stress distribution along the joint interface during the tensile test, leading to the high load‐bearing capability of the SRW joints. The maximum average tensile force is 1.5 kN. The fracture occurs across the polymer composite rather than along the joint interface. In the results, it is shown that SRW has the potential to be developed into a method for fabricating reliable hybrid joints for the aerospace and automotive industries.

Advances and applications of metal-polymer hybrid for load-bearing body-in-white structural components: a comprehensive review

Advances and applications of metal-polymer hybrid for load-bearing body-in-white structural components: a comprehensive review

Electrical and Dielectric Properties of Polymer-Metal Hybrid Nanocomposites - A Short Review

Polymer-metal hybrid nanocomposites have garnered significant attention in recent years due to their exceptional electrical and dielectric properties, which find applications in a wide range of industries, including electronics, energy storage, and advanced materials. This review article provides a comprehensive overview of the current state-of-the-art in the field of polymer-metal hybrid nanocomposites, with a particular focus on their electrical and dielectric properties. The first section of the review delves into the synthesis and fabrication techniques employed to create these nanocomposites, highlighting the importance of controlling the dispersion and distribution of metal nanoparticles within the polymer matrix. Various approaches, such as in-situ polymerization, melt mixing, and electrospinning, are discussed in detail, along with their respective advantages and limitations.The subsequent sections explore the influence of metal nanoparticles on the electrical conductivity and dielectric constant of the nanocomposites. The role of factors such as nanoparticle size, shape, and concentration in determining these properties is thoroughly examined. Moreover, the impact of metal surface modifications and the choice of polymer matrix on enhancing electrical and dielectric performance are also addressed. In addition to discussing fundamental aspects, this review highlights practical applications of polymer-metal hybrid nanocomposites in the development of high-performance capacitors, sensors, electromagnetic shielding materials, and flexible electronics. The potential for these materials to revolutionize various technological sectors is discussed, emphasizing their role in advancing miniaturization, energy efficiency, and durability. Furthermore, the review outlines current challenges and future prospects in the field, including the need for a deeper understanding of the underlying mechanisms governing electrical and dielectric behavior in these nanocomposites. Emerging trends such as the incorporation of 2D materials and the development of multifunctional hybrid systems are also explored, hinting at exciting avenues for further research and innovation. In conclusion, polymer-metal hybrid nanocomposites offer a promising platform for tailoring electrical and dielectric properties to meet the demands of modern technology. This review serves as a valuable resource for researchers, engineers, and scientists seeking to explore the potential of these materials and drive advancements in the field of electrical and dielectric engineering.

Ultra‐high bonding strength of carbon fiber–doped polyamide–aluminum alloy composite structure achieved by changing crystallinity

AbstractLightweight and high‐strength polymer–metal hybrid structures are favored for reducing material and energy consumption. In this study, carbon fiber‐reinforced polyamide 6 (CFPA) composite materials were prepared through melt blending, and 30 wt% CFPA exhibited the highest shear strength and lowest shrinkage rate among other carbon fiber contents. With pretreatments of anodizing and etching treatment, injection molded direct joining was employed to create polyamide 6 (PA)/CFPA–Aluminum alloy (Al) composites. The impacts of the injection temperature and speed on the bonding strength of the PA/CFPA–Al composite materials were investigated. The characterization results confirmed that carbon fiber doping reduces the coefficient of linear thermal expansion (CLTE) and enhances crystallization ability of PA. The higher injection temperatures and lower injection speed significantly increase the crystallinity of PA and the infiltration of the molten polymer into the nanoporous anodic aluminum oxide films. When the injection temperature was 270°C and the speed was 6 mm/s, the bonding strength of the PA–Al hybrid structure reached a maximum of 36.6 MPa. When the injection temperature was 300°C, the bonding strength of the CFPA–Al hybrid structure reached a maximum of 40.8 MPa. Adhesive parts with high shear bonding strength are critical to satisfying engineering requirements and have significant potential, particularly in polymer–metal composite structures. The polymer‐metal hybrid structure can meet the high interfacial bonding strength required in most engineering applications.Highlights Injection temperature and speed in IMDJ affect PA crystallinity. Carbon fiber doping reduces the CLTE of PA and increases the shear strength. High temperatures and low injection speeds are beneficial to adhesives. The bonding strength of PA–Al reached a maximum of 36.6 MPa. The bonding strength of CFPA–Al reached a maximum of 40.8 MPa.

An efficient/accurate multi-scale fatigue prediction method for Metal-Polymer hybrid (MPH) interface

Metal-polymer hybrid (MPH) structures, featuring a micro-structure interlocking design, combine the high strength of metal with the exceptional formability of polymer-based composites and have gained significant attention in automotive load-bearing components. Challenges persist in accurately predicting MPH structure fatigue life using small samples with diverse interlock parameters and swiftly generating static strength and fatigue life response surfaces for automated optimization. We introduce a simplified model for predicting fatigue at the interfaces of MPH structures. Our multi-fidelity prediction method integrates this model with limited high-fidelity data samples to assess both the static strength and fatigue life effectively. This method predicts the deviation with less than 3% error compared to FSR-FEM, achieving a reduction in prediction time of over 60%. Additionally, we elucidate the non-synergistic mechanisms of key interfacial locking parameters between static strength and fatigue life at the micro-scale. Finally, we propose and apply a multi-objective synergistic optimization strategy to the MPH thrust rods in vehicles. By utilizing our optimization method, we achieve a 27.9% weight reduction compared to steel counterparts, while enhancing overall tensile strength by 11.8% and significantly improving fatigue life by 46.7% compared to MPH torque rods lacking an interlock interface.

Highly Electroconductive Metal-Polymer Hybrid Foams Based on Silver Nanowires: Manufacturing and Characterization.

Due to their electroconductive properties, flexible open-cell polyurethane foam/silver nanowire (PUF/AgNW) structures can provide an alternative for the construction of cheap pressure transducers with limited lifetimes or used as filter media for air conditioning units, presenting bactericidal and antifungal properties. In this paper, highly electroconductive metal-polymer hybrid foams (MPHFs) based on AgNWs were manufactured and characterized. The electrical resistance of MPHFs with various degrees of AgNW coating was measured during repeated compression. For low degrees of AgNW coating, the decrease in electrical resistance during compression occurs in steps and is not reproducible with repeated compression cycles due to the reduced number of electroconductive zones involved in obtaining electrical conductivity. For high AgNW coating degrees, the decrease in resistance is quasi-linear and reproducible after the first compression cycle. However, after compression, cracks appear in the foam cell structure, which increases the electrical resistance and decreases the mechanical strength. It can be considered that PUFs coated with AgNWs have a compression memory effect and can be used as cheap solutions in industrial processes in which high precision is not required, such as exceeding a maximum admissible load or as ohmic seals for product security.

Effect of Process Parameters on Joint Performance in Hot Pressure Welding of 6061 Aluminum Alloy to CF/PA66.

Polymer-metal hybrid structures combine the merits of polymer and metal materials, making them widely applicable in fields such as aerospace and automotive industries. However, the main challenge lies in achieving efficient and strong connections between the metal and polymer components. This paper uses the jet electrochemical machining (Jet-ECM) method to customize the surface morphologies on 6061 aluminum alloy (AA6061) sheets. The connection between AA6061 and carbon fiber-reinforced PA66 (CF/PA66) is then achieved through hot pressure welding (HPW). The effects of aluminum alloy surface morphology, welding force, and welding time on the mechanical properties and microstructure of the joint are investigated. The optimal process parameters are determined by the design of the experiment. The results show that the aluminum alloy surface morphology has the greatest impact on the mechanical property of the welded joint. The optimal process parameters are surface morphology with wider, shallower, and sparsely distributed grooves on the aluminum alloy surface, the welding force is 720 N, the welding time is 12 s, the welding temperature is 360 °C, the cooling time is 16 s, and the optimal peak load of the joint is 6690 N. Under the optimal parameters, the fracture morphology in the AA6061 side is almost entirely covered with CF/PA66. The joint experiences cohesive failure in most areas and fiber-matrix debonding in a small area.

High bonding strength of polyphenylene sulfide-aluminum alloy composite structure achieved by constant current anodizing in tartaric acid

The high-strength and facile direct joining of metal to polymer has attracted increasing attention in adhesion. The aluminum alloy (Al) specimen was fabricated by constant current anodization and enlarging treatment. The influences of surface energy, porosity, and anodization time on the interface bonding strength of the injection molding polyphenylene sulfide (PPS)–Al composite structures were quantitatively discussed. Results showed that the bonding strength of the joints was significantly affected by the wettability, porosity, thickness, and pore diameter of the anodized aluminum oxide (AAO) films. When the current density and anodization time were 120 A/m2 and 30 min, the Al surface energy and the bonding strength reached the maximum of 74.8 mN/m and 11.7 MPa. With the enlargement treatment of the AAO film, when the etching duration was 45 min, the bonding strength increased to 25.0 MPa. In general, these results are of great importance to the further design and optimization of the polymer-metal hybrid with reliable interface adhesive strength.

A novel joining technology for metal and polymer sheets

This paper introduces a novel joining process for producing hybrid metal-polymer joints. The process, called hole hemming, involves deforming the metal sheet to establish a mechanical interlock with the polymer sheet, requiring neither heating nor auxiliary elements. The applicability of this process is tested for joining aluminum and polycarbonate (PC) sheets. Initially, an analytical design method is presented to achieve a connection without failure and with a mechanical interlock. Subsequently, the accuracy of the predictions is assessed through experiments and finite element simulations, employing the modified Mohr-Coulomb criterion for the prediction of ductile damage. Additionally, a new design for hole-hemmed joints, involving the incorporation of branches in the hole of the outer sheet, is introduced to expand the process window of this novel joining technology. Finally, the mechanical behavior of four different types of hybrid hole-hemmed joints (HHH joints) are evaluated through single-lap shear tests. The results show that the hole hemming process can successfully join AA6082-T4 and PC sheets, validating the proposed designs and ideas. The new hybrid joints demonstrate a maximum force and displacement of 1.6 kN and 12.9 mm, respectively, in the shear test, indicating significant potential of the proposed technology for joining metal and polymer sheets.

Fabrication of phase change microcapsules with polymer-metal hybrid shell and their utilization potentiality in gypsum composites for energy conservation

This study fabricated a kind of novel phase change microcapsules with a metal-polymer hybrid capsule shell for applying in gypsum materials to reduce building energy consumption. The microstructure, composition and thermal characteristics of the microcapsules were investigated by using techniques such as the scanning electron microscope, Fourier transform infrared spectroscopy, X-ray photoelectron spectroscopy and differential scanning calorimetry. Their impact on the thermal regulation characteristics of gypsum composite materials was also analyzed through the heating plate test and simulated room experiment. Results show the microcapsules with inner organic polymer and outer copper layer were successfully fabricated. And they exhibited a phase change temperature between 22.3 ℃ and 23.3 ℃ and latent heat between 82.2 J/g to 139.5 J/g. Meanwhile, the thermal inertia and thermal storage capacity of gypsum composites were enhanced by incorporating the final microcapsules. After heated for 40 min, the gypsum composite board with MPCM-Cu shows the ability to reduce the room temperature fluctuation. Furthermore, the thermal performance of MPCM-Cu remains stable after 250 thermal cycles. These results indicate that final microcapsules exhibit the potential for building energy conservation.

Experimental characterization of a Polymer Metal Hybrid (PMH) automotive structure under quasi-static, creep, and impact loading

A feasibility study on a short fibre reinforced Polymer Metal Hybrid (PMH) solution of a car’s suspension control arm has been conducted through a simplified demonstrator, representative of the most critical portion of this component. It was injection moulded in two versions: an all composite one and a PMH version, in which the short fibre reinforced composite was over-moulded on to an aluminium insert. The demonstrator underwent quasi-static, creep and impact tests to simulate most of the loading conditions experienced by a suspension arm during its lifetime. The mechanical behaviours of the two demonstrator versions were compared to highlight the differences introduced by the proposed novel PMH solution. In particular, the ductile metal insert ensured the compliance of the PMH demonstrators with the automotive specific safety requirement of avoiding the complete separation at failure, which was successfully obtained in all testing conditions.

Experimental evaluation of T-peel strength on functionally graded Al5083 and HDPE tri-laminated composites fabricated by colding-assisted friction stir additive manufacturing

Functionally graded composites offer impressive promise in overcoming the inherent weaknesses of Metal-polymer hybrid structures. In this study, functionally graded 5083 aluminum (Al5083) and high-density polyethylene (HDPE) tri-laminated composites were fabricated by colding-assisted friction stir additive manufacturing (CA-FSAM) and friction stir additive manufacturing (FSAM). Functionally graded laminate composites have been used to overcome these drawbacks by varying the thickness of the raw laminate. The thickness changes in the user sheets were functionally 0.75 mm compared to the previous laminate. Finally, the initial sheets were transformed to three thicknesses: 3, 2.25, and 1.5 mm. The bond strength between the sheets was measured using the T-peel test. In the T-peel test, the initial crack length was 25 mm and the length of the weld zone was 111 mm. The results showed that the bond strength between the laminates improved with cooling after the CA-FSAM process. The bond strength is essentially determined by the amount of covalent bonding, which, in turn, is a function of the density on the treated surface. Dislocation forest at the surface of the tri-laminate composite can be considered a consequence of T-peel test. The joining mechanism could be ascribed to mechanical interlocking, adhesion bonding at the interface of the Al5083 alloy and HDPE polymer, and metal-chip reinforcement in HDPE of the stir zone. The maximum force (Fmax) obtained in the FSAM and CA-FSAM specimens were 1057.58 and 1254.20 N, respectively. Average force of T-peel test (Favg peel) obtained in the FSAM and CA-FSAM specimens was 984.36 and 1024.32 N, respectively.

Improving bonding strength of aluminium-PEEK hybrid metal-polymer joints by two-step laser surface treatment

The present study investigates the adoption of laser surface treatments to improve the bonding strength of dissimilar material hybrid structures made by the thermomechanical joining process. Aluminium AA7075 alloy was joined to Polyether-ether-ketone through a friction-assisted joining process. For the surface treatment, a two-step laser treatment was adopted. The latter consists of a first phase, called laser texturing, where a deep square grid texture is obtained by adopting high pulse energy and repetitions, followed by a further laser treatment, called cleaning, carried out with lower energy content, and applied over the overall adhesion surface. Two textures characterised by different grid sizes (200 and 300 µm) were realised. As received, uncleaned, and only cleaned samples were adopted as reference treatments. The results indicated that laser cleaning performed after laser texturing enabled a significant improvement of adhesion irrespective of the previous laser texturing strategy. This was also confirmed by the higher amount of polymer trapped within the laser-texturized paths. The only laser cleaning treatment enabled the successful joining of the substrates with an average shear strength of 12 MPa. On the other hand, when texturing with a hatch distance of 200 μm, laser cleaning performed after texturing increased the shear strength from 18.4 MPa to 25.2 MPa corresponding to an increase of 37%. The increased adhesion between the PEEK and the aluminium was also indicated by the change in the failure mode of the joints. The texturized samples with a hatch distance of 200 μm failed by pull-out; when the laser cleaning was performed on these samples, they failed by cohesive failure.

Evaluation of wear test on functionally graded metal-polymer tri-laminate composite interfaces of cooling-assisted friction stir additive manufacturing

In this study, a new friction stir welding (FSW) based additive manufacturing (AM) process called "cooling-assisted friction stir additive manufacturing (CA-FSAM)" was introduced to join sheets of metal-polymer hybrid structures (MPHS). Dry ice was introduced as the coolant. Thickness variations of the raw high-density polyethylene (HDPE) and 5083 aluminum alloy (Al5083) sheets were functionally graded at a rate of 0.75 mm from the former layer. The arrangement of layers in terms of thickness was arranged in the order of 3, 2.25, and 1.5 mm. Functionally graded metal-polymer tri-laminate composite fabricated with CA-FSAM technology was investigated using the pin-on-disk wear test. The results showed that mechanical locking between the layers affected the bond strength. Cross-sectional morphology examination revealed defect-free, strong joints. X-ray diffraction (XRD) results confirmed the formation of Mg2Si; however, the XRD peak was low, indicating a slight effect on the interface properties. Thermal gravimetric analysis (TGA)-Fourier transform infrared spectroscopy (FT-IR) characterization highlighted that the main evolved products during tri-laminate composite joining were CO, CC, CH3, CH2, and CH2. Oxidation occurred in the FTIR peak in the absorption band (1029.92 cm−1 to 1370.63 cm−1). Disk loading resulted in the buildup of an internal drag force that caused the dislocation/rupture of the CC or CH bonds. Defects, such as deep grooves, pits, and delamination at the interface, were observed in the composite specimen. The wear path was not visible in the worn composite material. The wear rate at 4 kg load on Al5083, HDPE, and metal-polymer tri-laminate composite specimens was 3.15 ± 0.22, 4.72 ± 0.36, and 3.42 ± 0.18 × 10−6 mm3/N. m, respectively.

Self-Pierce Riveting: Development and Assessment for Joining Polymer-Metal Hybrid Structures in Lightweight Automotive Applications.

In recent years, the transportation industry has faced the challenge of cutting costs, meeting increasingly stringent environmental regulations, and significantly increasing transportation volumes. One approach to meeting these challenges is to develop new, improved transportation vehicles using new materials and innovative joining techniques. Multi-material structures are becoming an alternative to body parts. Self-pierce riveting technology plays a crucial role in this process, and hybrid structures depend exclusively on it. In this article, recent advances in self-pierce riveting technology are analyzed to meet today's challenges and future multi-material applications.

Moisture-induced defects produced by direct laser joining of AA7075 aluminum and PEEK

The present investigation aims to determine how polymer moisture and volatile compounds influence the mechanical behavior of hybrid metal-polymer joints made by Laser-Assisted Joining. Experimental laser joining tests were performed on AA7075 aluminum alloy and Polyetheretherketone (PEEK). Some polymer samples were pre-treated through drying to remove the moisture stored in the PEEK before joining. Laser spot joints were produced with dried and as-received samples at different heating times. Different characterization techniques were adopted to determine the influence of moisture on the performance of the joints. Single lap shear tests were performed to assess the mechanical behavior of the joints. Fracture surface analysis was carried out through Optical Microscopy to determine the influence of the moisture content on the mechanical behavior. The results indicated a significant influence of moisture on the mechanical behavior of the joints. This led to the formation and coalescence of voids at the metal-polymer interface that affected the mechanical behavior of the joints. Dried samples were characterized by higher shear force (up to 33 %) and higher toughness (up to 130 %) compared to as-received samples.

Studies on process parameter optimization and surface modification for joint strength enhancement of laser welded Aluminium 5754-Polyamide hybrid joints

Hybrid metal-polymer structures offer several desirable features and are often employed in aviation, automobiles, and biomedical industries. Multi-material combinations, such as aluminium alloys and polymers, are increasingly utilized in the aircraft and automobile industries to improve the strength-to-weight ratio of respective parts and components. Various techniques, including adhesive bonding and mechanical fasteners, have been utilized to join sheets of metal alloys and polymers. However, the higher processing time of adhesive bonding and the additional weight caused by mechanical fasteners are the most significant drawbacks of these processes. To circumvent these limitations, laser beam welding is a viable alternative for joining polymer and aluminium alloys. Moreover, in several engineering sectors, there is a strong demand for different metal-polymer joints in lightweight hybrid structures. This research discusses an experimental investigation on laser direct joining of aluminium 5754 and polyamide (PA). The influence of process parameters of laser welding such as laser power, laser welding speed, and laser defocus on the tensile shear load was investigated. Response surface methodology based on the box-behnken design establishes mathematical relationships between control factors and outputs. Validation and optimization experiments were carried out to ensure the feasibility of the model. The findings demonstrate a strong correlation between the predicted and actual values. The findings indicate that the tensile shear load improves by increasing the laser power and decreasing the welding speed. The detrimental effect in tensile shear load is noticed at lower and higher defocus values. A maximum failure load of 1062 N was achieved under the optimal parameter setting of laser power of 1.6 kW, a laser welding speed of 2 mm/s, and a laser defocus of 9 mm. Later surface modifications such as emery sheet grinding, laser ablated dimples, and laser surface texturing, were performed on the aluminium surface to enhance tensile shear load. The surface modification resulted in a variation in surface roughness values between 0.34 µm and 52.7 µm. The result indicates that while using a square texture geometry of grid width of 214 µm, depth of 255 µm, the surface roughness of 27.79 µm, and a depth-to-width ratio of 1.19, a maximum shear failure load of 1563 N is achieved. This work proposes a novel surface laser treatment method for improving the joint strength of metal-polymer hybrid joints.