A Simple Surface Treatment for Improving the Adhesive Bonding Properties and Durability of an AlMg₃ Alloy

The structural adhesive bonding of aluminum is widely used in the aircraft and automotive industries. The surface preparation of aluminum prior to adhesive bonding plays a significant role in improving the bonding strength. Surface cleanliness, surface roughness, and surface chemistry can be controlled, primarily, by proper surface treatment methods. In this study, the effect of varying the chemical treatment period on the adhesive bonding characteristics was investigated. An epoxy adhesive was used to join the treated surfaces, and the bond strengths were evaluated via single lap-shear (SLS) tests in pristine, as well as degraded, conditions. The surface morphology, chemistry, and corrosion properties of the surfaces with chemical treatments were characterized using various surface analytical tools, such as scanning electron microscopy, an energy dispersive spectrometer (SEM/EDX), and an electrochemical workstation. Excellent adhesion characteristics, with the complete cohesive failure of the adhesive, were encountered on the surfaces of the H₂O₂-treated samples. The H₂O₂-treated samples exhibited the highest initial bond strength, reaching 22.5 ± 0.5 MPa, and showed a decrease of only 10% (to 18.1 ± 0.2 MPa) after aging under extreme humidity and temperature conditions (70 °C and 100% R.H. for 4 weeks). The chemical treatment reported in this work is a very simple method to produce durable joints.