Shock Test Research Articles

Enhancement of strength and thermal shock resistance of MgO‐MgAl2O4 ceramic filters with microporous MgO powder: Effect of α‐Al2O3 micro‐powder content

AbstractIn this work, MgO‐MgAl2O4 ceramic filters were fabricated from microporous MgO powder and α‐Al2O3 micro‐powder, in which microporous MgO powder was prepared using Mg(OH)2 as initial raw material. With the α‐Al2O3 micro‐powder content increased from 0 to 15 wt%, the tight packing and reaction sintering between MgO microparticles and Al2O3 microparticles promoted the formation and growth of magnesium aluminate spinel necks, reduced the apparent porosity of ceramic filter skeletons, decreased the pore size, and improved the strength of the filters. When the α‐Al2O3 micro‐powder content further raised to 20 wt%, the thermal mismatch between MgO microparticles and spinel microparticles caused a small amount of crack generation, which lowered the strength of the filter. Besides, after introducing the α‐Al2O3 micro‐powder, more spinel necks were produced due to a small amount of MgO solid dissolved in the spinel lattice during the thermal shock test, which enhanced the thermal shock resistance of the filters. When the α‐Al2O3 micro‐powder content was 15 wt%, the filter had excellent comprehensive performance, the bulk density and apparent porosity of the filter skeleton were 3.09 g/cm3 and 10.7%, and the compressive strength before and after thermal shock test was 3.48 and 3.70 MPa, respectively.

Performance-tunable thermal barrier coating for carbon fiber-reinforced plastic composites via flame spraying

Thermal barrier coatings (TBCs) are essential for improving the heat resistance of materials operating in high-temperature environments. This paper proposes a new method for manufacturing double-layered TBC with graded porosity for carbon fiber-reinforced plastic (CFRP) composites. The TBC was created by a flame spraying process, consisting of relatively dense and porous layers: (1) a dense layer was produced by spraying yttria-stabilized zirconia (YSZ) particles directly onto neat carbon fabric substrate and (2) a porous layer was prepared by co-spraying YSZ particles with sacrificial polyetheretherketone (PEEK) particles. The porosity of the porous layer was controlled by varying a PEEK injection distance (D) and a PEEK feed rate (R). The correlation between porosity and thermal conductivity of the TBC layer was investigated to assess its thermal barrier performance. The TBC fabricated with the D = 5 cm and the R = 1.0 g/min offered the optimal porosity and conductivity. The 640μm-thick TBC with 34% porosity and 0.27 W/m·K thermal conductivity protected the CFRP substrate remarkably under the subjected torch at 500°C, as the TBC layer reduced the surface temperature of CFRP to 230°C. Thermomechanical analysis, following thermal shock tests, revealed that the double-layered TBC/CFRP composite retained 87% and 75% of its pristine flexural strength and modulus, respectively, while the neat CFRP composite was completely burnt out. This study explored the application of flame spray technology to develop highly effective double-layered TBCs with tunable porosity to maximize their thermal barrier performances. All results from the current study provide new insights into the design and development of TBC and CFRP composites, which will benefit a wide range of lightweight high-temperature applications.

Calibration of Jones–Wilkins–Lee equation of state for unreacted explosives with shock Hugoniot relationship and optimization algorithm

The unreacted equation of state (EOS) for an unreacted explosive can provide fundamental information to understand any analytical model for the shock and initiation process. Based on the Hugoniot expression in Jones–Wilkins–Lee (JWL) form derived from the Mie–Grüneisen EOS and conservation equation across the shock wave, a three-point calibrating method to determine the JWL EOS parameters for unreacted explosives was developed using intelligent algorithms and shock Hugoniot relationship of the explosives considered. The calibration method proposed utilizes the back propagation neural network to predict the nonlinear system composed of different JWL parameter sets; the genetic algorithm is then used to find the optimal solution of the JWL parameter set. Unreacted JWL EOS parameters of eight typical explosives were calibrated using the calibrating method developed, and an excellent agreement can be observed between JWL EOS and experimental p–v curves for all eight explosives selected, indicating the high accuracy of the three-point calibrating method. However, the effectiveness of the three-point calibrating method was experimentally validated with the experimental data measured from the shock tests of the dihydroxylammonium 5,5′-bitetrazole-1,1′-dioxide (TKX-50)-based explosive, where the JWL p–v curve derived from the three-point calibrating method is in good agreement with the experimental curve.

Improved thermal shock reliability of Ag paste sintered joint by adjusted coefficient of thermal expansion with Ag-Si atomized particles addition

In this study, two kinds of atomized Ag-20 wt%Si and Ag-50 wt%Si particles are fabricated and added to Ag paste to fabricate composite pastes to achieve a low coefficient of thermal expansion (CTE), and their performance stability in SiC power module is evaluated under thermal shock from −50 to 250 °C. Four kinds of composite Ag pastes using the two kinds of atomized Ag-Si addition with 10 % and 30 % were obtained, AS20-10, AS50-10, AS20-30 and AS50-30, respectively. The results show that the CTE reduction intensifies with increasing Ag-Si atomized particle content. The retention ratio of shear strength of AS20-30 sintered joint after 1000 cycles was 102.3 %, which means the shear strength did not decrease during so harsh thermal shock test. The mechanism was discussed in detail. In addition, the properties such as thermal conductivity and electrical conductivity for the composite pastes were also evaluated to gain a more comprehensive understanding for the new materials especially for the design of SiC power modules with a long-time life. Comprehensively considering the material parameters of the composite pastes and the reliability of the sintered joints under thermal shock, the optimized composite pastes as die attach material in power electronics are obtained. The findings should be inspiring in developing novel die attach materials for high reliable interconnections in SiC power modules.

Analysis of BGA Lead-Free solder joints failure behavior based on thermal shock testing

The interconnected solder joints within automotive electronic components are the most vulnerable parts of the structure, and their reliability is crucial for the development of new energy vehicles. This study focuses on automotive ADAS (Advanced Driver Assistance System) devices, analyzing the failure behavior of internal BGA (Ball Grid Array) lead-free solder joints under thermal shock conditions.Through thermal shock testing from −40℃ to 95℃, it was observed that microcracks first appeared in the upper intermetallic compound (IMC) layer of corner solder joints after 1600 cycles. As the number of thermal shock cycles increased, the net-like β-Sn phase in the solder joints gradually transformed into block and dot-like structures. Due to the relatively weak strength between the IMC layer and the Ag-Sn compound region, cracks typically propagated along the boundaries of these areas. Recrystallization occurred in the interface between the solder joint and the upper pad, with the proportion of high-angle grain boundaries increasing from 10.74% to 72.43%. The crack propagation mode changed from initial intergranular to transgranular fracture. Throughout the thermal shock test, the upper IMC layer remained thicker than the lower one, with the lower IMC layer thickness showing a minimum point at 750 cycles.The average thrust force between the solder joints and the substrate decreased more rapidly with thermal shock cycles, indicating that non-solder mask defined pads are more effective in improving structural strength.

A novel design of compact elastomer shock absorption system to protect sensitive objects from underwater shock for naval application

This research paper proposes a unique way to safeguard delicate systems on submerged platforms from the undesirable effects of underwater explosion shock loads. The underwater detonation of an explosive charge and mines produce devastating underwater shocks against underwater platforms. Shock load developed underwater has been analyzed, and a shock response spectrum (SRS) approach to compute shock peak responses has been adopted. SRS shock absorption frequency satisfies requirements for both shock absorption and delicate systems. The shock load was reduced to 2g by altering the delicate system stiffness and damping properties. The analytical model for a single DOF system was formulated, and simulation was carried out using ANSYS solver. The stiffness has been spread across various points along the length of the delicate system, allowing it to undergo translational oscillations when subjected to shock loads. This research paper presents an innovative design approach for a shock absorption system intended for underwater sensitive objects, emphasizing simplicity, distinctiveness, compactness, reliability, and electromagnetic compatibility. Experimental testing validated the shock absorption design on the prototype. Shock testing determined the absorber’s maximum displacement and sensitive object acceleration.

A sandwich-structured 1-3 type piezoelectric composite material for enhancing reliability

This study proposes a sandwich structure 1-3 piezoelectric composite, incorporating flexible silicone rubber to enhance the thickness vibration mode of piezoelectric ceramics. Rigid aluminum nitride (AlN) is employed to bolster the mechanical stability of the composite. Utilizing equivalent parameter theory, we establish a mathematical model for the sandwich structure composite material. The impact of the piezoelectric phase size and the volume fraction of AlN on several performance parameters of the material are analyzed, including the thickness electromechanical coupling coefficient, density, sound velocity, and characteristic impedance. The sandwich structure piezoelectric composite was fabricated using the "cutting and filling" technique. Experimental outcomes reveal that this material demonstrates concentrated thickness vibration modes, with a thickness electromechanical coupling coefficient reaching as high as 0.72, a 16.6 % increase compared to traditional 1-3 piezoelectric composites. Results from thermal shock tests and tensile tests suggest that the sandwich structure 1-3 piezoelectric composite has considerable potential for use in highly reliable low-frequency receiving transducers.

Stress–strain behaviour and degradation mechanism of low–carbon MgO–C refractories at 900–1100 °C: role of TiB2–BN–AlN waste

The use of boron–containing additives often raises concerns when exposed to high temperatures. In this study, the high temperature stress–strain behavior and degradation mechanism of low–carbon MgO–C refractories containing TiB2–BN–AlN waste were investigated. Stress–strain curve, peak axial stress, Young’s modulus, cohesion, and residual strength ratio after thermal shock tests were thoroughly analyzed. The findings suggest that the mechanical properties of refractories remain unimpaired within the temperature range of 900–1100 ℃, and can even be enhanced through the synergistic effect of TiB2–BN–AlN waste and Al powder. The optimized axial stress increased from 55.0 to 62.0 MPa at 1100 ℃, while the cohesion increased from 10.0 to 13.8 MPa, respectively. The observed enhancement can be primarily attributed to the effective healing of pores and cracks, reduction in oxidation, and improved material cohesion. However, the excessive incorporation of boron–containing waste may compromise the performance of refractories, leading to instability or degradation.

Modeling and identification of hysteresis of marine damper considering shock environment based on evolutionary sparrow search algorithm

The mechanical properties of marine dampers are usually highly nonlinear in order to adapt to dynamic and shock environments. The dampers are subjected to dynamic and shock tests and the hysteresis curves are found to be rate-dependent and asymmetric. To be able to describe the dynamic hysteresis and shock hysteresis, a rate-dependent generalized Prandtl-Ishlinskii (RDGPI) model is proposed based on the generalized Prandtl-Ishlinskii (GPI) model, which is a hybrid of the GPI model and the radial basis function (RBF) neural network. Due to the large number of parameters in the model, thus aiming to improve the effect of parameter identification, an evolutionary sparrow search algorithm mixed with sparrow search algorithm and differential evolutionary algorithm is proposed. Compared with other algorithms, sparrow search algorithm is verified to have ideal optimization effect and convergence speed, and it is not easy to fall into the local optimum. Finally, the RDGPI model is experimentally verified, and the results show that the prediction error of the RDGPI model for dynamic hysteresis is within 0.06 kN, and the prediction error for shock hysteresis is within 0.8 kN, which is capable of describing the rate-dependent characteristics of the damper hysteresis. And it has a very good generalization ability, which makes it very suitable to be used in the modeling of the mechanical characteristics of the marine damper.

Evaluation of the mechanical shock testing standards for electric vehicle batteries

The safety of Li-ion batteries (LIB) has become an important issue with the continuously increased use of electric vehicles (EV) in the world. In a survivable vehicle crash, when the vehicle needs to maintain structural integrity, crash-induced shock may damage EV's LIB. Therefore, an evaluation of commonly used mechanical shock test standards for EV battery module and pack is performed in this study against the crash-induced shock signals collected from National Highway Traffic Safety Administration (NHTSA) New Car Assessment Program (NCAP) tests. Various shock analysis methods including signal characteristics in time domain, power spectral density (PSD) and shock response spectrum (SRS) in frequency domain, and the acceleration/velocity-change diagram are used for the evaluation. It is found that most peak accelerations of NCAP shock signals significantly exceed the peak accelerations specified in shock testing standards. Crash-induced shocks cannot be fully represented by the half-sine pulse adopted in shock testing standards. In both time and frequency domains, the existing shock testing standards generally underestimate the severities of the crash-induced shocks, and therefore, are non-conservative. It also shows that the correct selection of a filter for the processing of the original crash-induced shock signal is crucial for the specification of EV battery shock environment and shock response analyses. The results obtained in this research can support the development of more reliable shock testing standards for EV batteries.

Enhanced thermal shock resistance and higher molten steel purification efficiency of Al2O3-MgAl2O4-C filter with in-situ β-SiC whiskers: Compared with Al2O3-C filter

The porous ceramic filter is mainly utilized in the final stage of molten steel casting and serves as an important means for adsorbing non-metallic inclusions in order to improve the quality of the steel. In this study, Al2O3-MgAl2O4-C filter (filter AM) was prepared from porous Al2O3-MgAl2O4 micropowder, and referenced Al2O3-C filter (filter A) was prepared from α-Al2O3 micropowder. The phase composition, microstructure, mechanical properties and purification efficiency on molten steel of filter AM were compared with filter A by XRD, SEM, EDS and immersion test with molten steel. The results indicate that the filter AM exhibited a uniform skeleton without cracks, and plenty of β-SiC whiskers were generated internally. However, there were some cracks in the strut of filter A with the formation of many SiC/SiO2 spheres inside. The different microstructures resulted in the retention rate of cold compressive strength after thermal shock test as high as 91.11 % for filter AM and only 58.06 % for filter A, respectively. According to the immersion test, an Al2O3-MgAl2O4 layer was formed on the rougher surface of filter AM and contributed to the adsorption of the inclusions, leading to about 80 % reduction in the quantity of inclusions of various sizes. The cleanliness of steel was significantly improved as the T.O content was reduced from 56.3 ppm to 11.7 ppm. Finally, the mechanisms underlying the enhancement of thermal shock resistance and the improvement of purification efficiency by porous Al2O3-MgAl2O4 micropowder were proposed.

Investigation on improving soldering reliability of large-scale LCCC devices with high-lead solder ball materials

Abstract Leadless Ceramic Chip Carrier (LCCC) is commonly used in high-density electronic packaging PCB boards. Due to the different thermal expansion of materials, the solder joints of LCCC devices are prone to stress and cracking after assembly, which leads to the failure of LCCC devices’ electrical performance. In this paper, the advantages and disadvantages of four solutions were analysed, and comprehensively considered the use of ball planting to alleviate thermal mismatch stress. After experimental verification, the thermal mismatch between the LCCC devices and PCB results in a lifespan of less than 200 cycles for direct assembly of the LCCC devices. Planting balls at the bottom of LCCC devices and soldering can effectively increase the lifespan of solder joints and improve product reliability. By analysing the SMT process, the bottom high-lead ball placement of LCCC devices was implemented, and environmental testing was conducted using temperature shock testing to demonstrate that bottom ball placement can extend solder joint life and improve reliability. This study provides a reliable soldering method for large-scale LCCC devices and provides a basis for improving LCCC reliability.

Numerical assessment of thermal insulation and stress responses in film-cooled turbine vane thermal barrier coatings under CMAS deposition conditions

Deposition of CaO-MgO-Al2O3-SiO2 (CMAS) significantly contributes to the spalling of thermal barrier coatings (TBCs) on turbine vanes. A thorough understanding of the thermodynamic properties during CMAS deposition is critical for advancing the lifetime design of TBCs. This study employs the CMAS gas thermal shock test to determine the deposition characteristics, which were then analyzed using the critical velocity model. The results of this analysis align closely with experimental outcomes. Based on the numerical simulation of the fluid-solid coupling method, we further explored the insulation efficiency and stress distribution in TBCs under CMAS deposition conditions. It was observed that CMAS predominantly accumulates on the pressure side and within the film pores of the vane TBCs, with minimal deposition on the suction side. Such deposition patterns result in an increased overall temperature of the vane, concurrently diminishing the TBCs' insulation efficiency. Specifically, CMAS deposition raised the maximum surface temperature of the vane by 100 K and decreased the peak insulation performance of the TBCs by 16 %. Additionally, the deposition induced higher stresses within both the TBCs and the underlying vane substrate, with a 7 % increase in the maximum principal stresses at the TBC surface and a 6 % increase in the substrate. Consequently, under CMAS deposition conditions, TBCs in regions of low insulation efficiency and high stress on turbine vanes are prone to cracking and subsequent spallation.

High-temperature oxidation and gas thermal shock studies of IC10 simulated specimens with thermal barrier coatings

PurposeThe purpose of this study is to investigate the effects of high-temperature oxidation tests and gas thermal shock tests on IC10 simulated components with thermal barrier coatings under different temperatures and oxidation times.Design/methodology/approachIn the high-temperature oxidation test, specimens were oxidized at three different temperatures of 850, 980, and 1,100 °C for durations of 10, 20, 50, 100, 200, and 300 h, respectively. In the gas thermal shock test, specimens were pre-oxidized for 10, 20, 50, and 100 h, followed by a high-temperature gas thermal shock test at 1,100 °C.FindingsIn the high-temperature oxidation tests, with increasing oxidation time, the oxidation layer thickened, and the air-film holes diameter decreased. The microstructure of the bond coat transitioned from strip-like to block-like, and internal cracks transformed from numerous and short to larger and deeper. Below the bond coat, a noticeable disappearance layer of strengthening phase appeared, with increasing thickness. The strengthening phase in the substrate transitioned from regular square shapes to circles as temperature increased. In gas thermal shock tests at 1,100 °C, the oxidation weight gain ratio increased with longer pre-oxidation times, whereas the erosion weight loss ratio gradually decreased.Originality/valueThe originality and significance of this study lie in its departure from the typical subjects of high-temperature oxidation and thermal shock tests. Unlike common research targets, this study focuses on IC10 simulative specimens with thermal barrier coatings and air-film holes. Furthermore, it investigates the effects of varying temperatures and oxidation durations.

The effect of changing the combustion chamber head structure on turbine blades under thermal shock test

When the high-pressure turbine guide blade works in the aero-engine, it is in the complex gas-heat environment of the combustion chamber and the turbine. The temperature distribution and strength of the blade affect the reliability and life of the aero-engine. In order to more accurately analyze the complex flow field aero-thermal parameters between the aero-engine combustion chamber and the turbine, this paper considers the influence of the non-uniform aero-thermal parameters of the combustion chamber outlet on the turbine. Taking the first-stage guide vane of an aero-engine turbine as the research object, the high and low temperature cycle thermal shock test was carried out to obtain the crack location and strength of the turbine guide vane, which provided a certain reference for improving the design of the turbine guide vane. Through the test, it is found that after 750 thermal shock cycles, fatigue cracks appear in four concentrated areas of the blade, which are distributed in the leading edge and trailing edge of the blade respectively. This shows that the temperature at the leading edge and trailing edge of the blade is higher, the heat load is higher, and the risk of damage and ablation is also the highest. Based on the experiment, the cross-component model of the combustion chamber and the blade is established. On this basis, four kinds of swirler structures at the head of the combustion chamber are designed. ANSYS FLUENT software is used to study the unsteady parameters such as the surface temperature of the guide vane under the influence of strong swirling flow. The numerical results show that when the rotation direction of the cyclone is counterclockwise, the temperature of the guide vane wall is more uniform. Compared with the clockwise rotation of the cyclone, the temperature is reduced by about 5 %, and the installation angle of the 50° cyclone blade is better than the installation angle of the 45° blade.

The contribution of different sperm parameters to better explain ram semen cryoresistance

In order to determine an effective procedure for explaining ram sperm cryoresistance and develop a new model for breeders classification, a retrospective study was conducted using sperm analysis data obtained over two consecutive years from a total of 82 sessions of ram semen cryopreservation. In each session, fresh ejaculates from eight males were collected via artificial vagina, pooled and frozen in liquid nitrogen vapors. After thawing, a total of 19,084 sperm tracks and 11,319 morphometric measurements were analysed. Clustering analyses were applied to establish motile and morphometric sperm subpopulations. Additionally, plasma and acrosome membrane integrity, as well mitochondrial activity using flow cytometry immediately after sperm thawing and following hypoosmotic shock test (HOST) was assessed. To develop a Ram Sperm Cryoresistance Index, Principal Component Analyses (PCA) using 22 variables were conducted. In the first PCA, the parameters that best explain cryoresistance include total motility (TM), motile subpopulation 2 (motSP2, which groups slow, very linear spermatozoa with low lateral head displacement), morphometric subpopulation 1 (morphSP1, grouping spermatozoa with the smallest head size and lowest shape values), sperm plasma membrane integrity immediately after thawing and following hypoosmotic shock test. These parameters collectively account for 77.34 % of the accumulated variance. To emphasize their importance, a second PCA was performed, revealing significant higher weighting coefficients for the quantity (TM) and quality (motSP2) of sperm movement after thawing, compared to the head size and shape of the thawed sperm (morphSP1). Furthermore, HOST Viability played a more decisive role than what was observed under isotonic conditions.

Low Current Density Cathode Plasma Electrolytic Deposition of Aluminum Alloy Based on a Bipolar Pulse Power Supply

The present paper reported a novel bipolar-pulse cathodic plasma electrolytic deposition (BP-CPED) technique with a low current density. This newly developed CPED technique can break down the barriers of the existing CPED technique with higher current density. In this report, ceramic coatings were successfully prepared on aluminum alloy via the BP-CPED technique in an aqueous carbamide-based electrolyte. Data recording results in the reacting process show that there is the current density of the cathode below 0.15 A/cm2 and that of the anode below 0.035 A/cm2, which approximately reaches the level of conventional MAO technique. Interestingly, the addition of PEG into the electrolyte can further reduce the current density and effectively improve the coating quality. The kinetic of the BP-CPED process was discussed based on the evolution of current density/voltage-time curves and spark discharge phenomena. SEM observations illustrate that BP-CPED coatings possess a typical porous-surface feature. XRD analysis indicates that the coating was mainly composed of Al2O3 and Al4C3. Al2O3/Al4C3/ZrO2 composite coatings fabricated after Zr-doping reflected the successful Zr-incorporation into the coating, which demonstrated that the BP-CPED technique can be used to design the coating composition by the doping modification. The direct pull-off and thermal shock tests confirmed that new BP-CPED coatings obtained under the cathodic plasma discharge have excellent bonding strength. It is possible that this novel BP-CPED technique can provide a promising choice in developing the large-area CPED surface treatment for the industrial application.

A review of thermal shock behavior of ceramics: Fundamental theory, experimental methods, and outlooks

AbstractThe thermal shock resistance of ceramics is a key factor for determining the durability of ceramic components under transient thermal conditions and is also one of the key factors for evaluating the stability of ceramics under extreme thermal conditions. After rapid heating or cooling, the surface and internal thermal stress mismatches of ceramics can cause severe thermal damage. Two main types of ceramic thermal shock exist: rapid cooling and rapid heating thermal shock. This article presents a broad understanding and insight into fundamental theory and experimental methods for ceramic thermal shock testing. The experimental equipment and procedures, test result evaluation, and material characterization of ceramic thermal shock are summarized. Moreover, outlooks and perspectives are discussed for testing and characterizing ceramic thermal shock resistance. This review will be helpful to researchers performing studies in the relevant fields of ceramics.

Thermal shock resistance of WC–Cr3C2–Ni coatings deposited via high-velocity air fuel spraying

In this study, the high-velocity air fuel (HVAF) spraying technique was used to deposit WC–Cr3C2–Ni wear-resistant coatings on the surface of crystallization rollers to overcome the wear problem of the substrate of thin-strip continuous-casting crystallization rollers and thus improve their efficiency. The performance and durability of the WC–Cr3C2–Ni coatings on the surface of the roller body during the actual continuous casting process were investigated by performing thermal shock tests. It was found that the thermal shock resistance of the closed-curved surface coatings increased with their thickness. The coatings exhibited the best thermal shock resistance at a thickness of 300 μm, and the number of cycles they could withstand at 800 °C reached 15. The results of the high-temperature wear tests showed that the WC–Cr3C2–Ni coatings deposited on the surface of the crystallization roller via HVAF reduced the friction coefficient of the surface of the roller body (from 0.425 to 0.362), and greatly reduced the wear loss volume during the wear process (reduced by 83 %). The WC-Cr3C2-Ni coating showed excellent resistance to crack initiation and propagation during wear and can be stabilized in long-cycle production and protect the substrate of the crystallization roller effectively. This study provides a theoretical basis for the selection and preparation of surface coatings for thin-strip continuous-casting crystallization rollers.

Structure and properties of the hot pressing molded anodized aluminum alloy/polyformaldehyde hybrids

The metal-plastic hybrid is one of the important solutions for lightweight and high-strength composite. The anodized aluminum alloy（AAA）/polyformaldehyde（POM） hybrids with excellent mechanical properties were processed by the hot pressing technology. The surface of the aluminum alloy plate was firstly pretreated with phosphoric acid and oxalic acid anodizing, resulting in a large number of micro-nano scale pores on the surface. These pores were well embedded with plastic melt during hot pressing to form micro-nano mechanical interlocking structures and the Al–O–C chemical bond at the interface is generated, thus ensuring good bonding strength at the metal and plastic interface. The maximum tensile-shear strength of the metal-plastic hybrid was 30.65 MPa, meanwhile, the metal-plastic interface failure presented mainly a mixed failure mode, including resin removal from the metal surface and plastic tearing from the plastic surface. At the same time, the salt spray test, thermal shock test, and variable temperature test were adopted to investigate the application performance of the metal-plastic hybrid. The Al/POM hybrids were able to maintain their mechanical strength above 20 MPa for 28 days in a salt spray environment, 14 times in a thermal shock cycle, and at high temperatures. The high mechanical strength of hybrid has good potential for automotive applications.