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The application of metal-polymer structures has been restricted by challenges in achieving effective bonding between the two materials. To address this, nano-TiO 2 coatings were introduced to improve the interfacial bonding between the treated 6061 Al alloy and carbon fiber-reinforced thermoplastic composite (CFRTP) during the laser joining process. The results highlighted that the joints created with nano-TiO 2 coatings achieved significantly higher tensile shear force and strength, reaching 1.43 and 1.37 times the values of those without particles, respectively. This improvement can be attributed to the following factors: firstly, the incorporation of coatings led to an increase in the absorption of hydroxy groups, thereby improving the wettability of the Al alloy, which in turn promoted the formation of hydrogen bonds at the interface. Secondly, the increased surface roughness favored the chemical interaction between the Al alloy and CFRTP, ascribed to the enlarged contact area. Moreover, this change influenced the thermal contact conductance (TCC), thereby changing the temperature at the interface and joining areas of the two materials. Finally, a notable transformation in the failure mode was observed, transitioning from adhesive failure to cohesive failure when compared to joints without nano-TiO 2 coatings. This underscored the reinforcing role played by nano-TiO 2 particles, providing an innovative solution for enhancing the interface bonding between dissimilar materials. [ABSTRACT FROM AUTHOR]

The application of metal-polymer structures has been restricted by challenges in achieving effective bonding between the two materials. To address this, nano-TiO 2 coatings were introduced to improve the interfacial bonding between the treated 6061 Al alloy and carbon fiber-reinforced thermoplastic composite (CFRTP) during the laser joining process. The results highlighted that the joints created with nano-TiO 2 coatings achieved significantly higher tensile shear force and strength, reaching 1.43 and 1.37 times the values of those without particles, respectively. This improvement can be attributed to the following factors: firstly, the incorporation of coatings led to an increase in the absorption of hydroxy groups, thereby improving the wettability of the Al alloy, which in turn promoted the formation of hydrogen bonds at the interface. Secondly, the increased surface roughness favored the chemical interaction between the Al alloy and CFRTP, ascribed to the enlarged contact area. Moreover, this change influenced the thermal contact conductance (TCC), thereby changing the temperature at the interface and joining areas of the two materials. Finally, a notable transformation in the failure mode was observed, transitioning from adhesive failure to cohesive failure when compared to joints without nano-TiO 2 coatings. This underscored the reinforcing role played by nano-TiO 2 particles, providing an innovative solution for enhancing the interface bonding between dissimilar materials. [ABSTRACT FROM AUTHOR]

• Achievement of high strength Al/CFRP hybrid joint via laser texturing pretreatment. • High friction stir joining speed which reached 3000 mm/min. • Establishing evaluation criteria of laser-textured joint: anchorage value. • Analysis including the semi-crystalline property of PA66 and temperature simulation. This paper presents the achievement of a high-strength Al/CFRP hybrid joint through a high-speed friction stir lap joining process, combined with variations in laser surface texturing pretreatment parameters. The study examined the impact of laser surface texturing parameters by varying the depth, interval distance and width of the laser texture. By adjusting laser texturing parameters, the softened PA66 was fully infused into the textured grooves on the aluminum surface, leading to a significant reduction in interfacial voids and cracks in Al/CFRP. The preliminary tensile shear test showed that the hybrid joint broke at the CFRP base material, indicating that the laser texturing exhibited excellent Al/CFRP interface strengthening ability. Further compression shear tests were applied to reveal the actual interfacial load-carrying performance for comparison. The maximum shear strength of 25. 5 − 1.34 + 0.7 MPa was achieved at a joining speed of 3000 mm/min. Additionally, a mathematical model was proposed to assess the strengthening impact of laser texturing parameters, considering micro-texture geometry and interfacial defects. The tearing of PA66, detachment of carbon fibers, and the breakage of carbon fibers were the three primary types of fracture modes identified at the Al/CFRP interface. The joining mechanism revealed that both mechanical interlocking and the chemical bonding of Al-O-C contributed to the increase in joint shear strength. This study presents a credible method for producing high-strength Al/CFRP lightweight structures. [ABSTRACT FROM AUTHOR]

• Investigate effect of various widths of laser textured groove on the joint. • Identify a new chemical bonding MgCO 3 at the interface after joining. • A number of AZ31B matrix was observed on the CFRTP at the interface. • The joints broke at the CFRTP base material after laser texturing. Laser texturing was performed on the surface of AZ31B magnesium alloy to increase the bonding strength. Textured AZ31B and carbon fiber reinforced thermoplastics (CFRTP) were then joined by the hot-pressing joining process. The effect of various groove widths of laser textured grid on the AZ31B/CFRTP joint was investigated. The research results showed that the wettability of the molten CFRTP on laser textured AZ31B was increased by about nine times, and the contact angle was reduced from 104.0° to 48.8° with a groove width of 0.3 mm. The macroscopic morphology and interface of joints had no defects, when the groove widths were 0.2 mm and 0.3 mm. The tensile-shear test was carried out, and the maximum tensile-shear force of the joint was 2698.8 N in the case of 0.3-mm groove width, which was 2.1 times as much as that of the untreated joint. The maximum tensile-shear force was 65.43% of the CFRTP itself. A diffusion layer of 9 μm– 24 μm thick formed at the AZ31B/CFRTP joint. MgCO 3 was identified at the joining interface. The mechanical interlocking and chemical bonding formed at the interface effectively improved the strength of the joint. [ABSTRACT FROM AUTHOR]