Mechanical property and structure of polycarbonate /aluminum alloy hybrid prepared by ultrasound-assisted hot-pressing technology

ABSTRACT Polycarbonate/aluminum alloy hybrids were prepared using a homemade ultrasound-assisted hot pressing molding (UAHPM) technique, and their properties and structures at the plastic-metal interface were also investigated. The aluminum alloy surface was chemically etched and anodized to form micron and nano-holes structures. The joint strength of 21.58 MPa was achieved at the optimum molding process by optimizing the process parameters of ultrasonic hot compression molding. The specific structure and morphology of the polycarbonate/aluminum hybrid material bonding layer were observed by field emission scanning electron microscopy (FE-SEM) using the ultrathin sectioning technique, and the plastic embedding depth reached about 3.8 µm under the optimal process conditions. X-ray photoelectron spectroscopy (XPS) analysis revealed that the bonding layer not only has a micro-nano interlocking structure but also forms an Al-O-C chemical bonding interaction. The plastic in the bonding layer was exposed by dissolving the aluminum alloy of the joint, and the filling form of the plastic in the micro-nanoholes was directly observed.