Improving adhesive bonding of short carbon fiber thermoplastic composites to aluminum alloys with a hybrid laser-plasma surface modification strategy

Lu, Brodey Z.; Qiao, Yao; Nickerson, Ethan K.; Shin, Yongsoon; Schuler, Gabrielle M.; Brown, Nate L.; Canfield, Nathan L.; Simmons, Kevin L.

doi:10.1016/j.matdes.2025.114501

Improving adhesive bonding of short carbon fiber thermoplastic composites to aluminum alloys with a hybrid laser-plasma surface modification strategy

Journal Article · Wed Aug 06 00:00:00 EDT 2025 · Materials & Design

DOI:https://doi.org/10.1016/j.matdes.2025.114501· OSTI ID:2578329

^[1]; ^[2]; Nickerson, Ethan K. ^[2]; ^[2]; Schuler, Gabrielle M. ^[2]; Brown, Nate L. ^[2]; Canfield, Nathan L. ^[2]; ^[2]

Northwestern Univ., Evanston, IL (United States)
Pacific Northwest National Laboratory (PNNL), Richland, WA (United States)

This study investigates hybrid laser–plasma surface modification strategies for metal–CFRTP (carbon-fiber-reinforced thermoplastic polymer) dissimilar joints to improve their bonding performance, in contrast to existing literature that mostly focuses on either plasma or laser treatment alone. By conducting double cantilever beam (DCB) tests on adhesively-bonded AA5052 and CFRPA66 (carbon-fiber-reinforced polyamide 66) joints, as an example of metal–CFRTP joints, it was found that laser engraving on the metal surface combined with plasma treatment on the CFRTP surface significantly improved the specific fracture energy of the joint by 187% and 31% compared to as-received and plasma-treated-only joints, respectively. However, the hybrid treatment of laser engraving and plasma on the investigated CFRTP surface did not improve the bonding performance of the joints. The underlying mechanisms related to hybrid laser-plasma surface modification strategies were further investigated by examining the surface and cross-sectional morphologies after DCB testing using microscopy. Computational modeling was performed to elucidate the interaction between grooves on the metal substrate and the CFRTP–adhesive interfacial bonding in metal–CFRTP joints. This study provides new insights into developing surface modification methods for achieving strong metal–CFRTP adhesive joints, aimed at lightweighting structural components in automotive, aerospace, and other applications.

View Accepted Manuscript (DOE)

Research Organization:: Pacific Northwest National Laboratory (PNNL), Richland, WA (United States)

Sponsoring Organization:: USDOE Office of Energy Efficiency and Renewable Energy (EERE), Office of Sustainable Transportation. Vehicle Technologies Office (VTO); USDOE Office of Science (SC)

Grant/Contract Number:: AC05-76RL01830

OSTI ID:: 2578329

Report Number(s):: PNNL-SA--211220

Journal Information:: Materials & Design, Journal Name: Materials & Design Vol. 257; ISSN 0264-1275

Publisher:: Elsevier BVCopyright Statement

Country of Publication:: United States

Language:: English

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