Surface Treatment for Improving Durability of Aluminum-Lithium Adhesive-Bonded Joints under Hot-Humid Exposure

The performance of adhesive-bonded joints, which are being increasingly used in the aerospace and automotive industries, under hot-humid conditions remains largely unknown. The effect of surface treatments on the strength durability of aluminum-lithium (Al-Li) alloy adhesive-bonded joints under hot-humid exposure was investigated. Varied surface characteristics were achieved by different mechanical and chemical treatments; combined mechanical and phosphoric acid anodization (PAA) treatments were also used. The adhesive-bonded joints were then exposed to a hot-humid environment. The surface morphology, strength degradation, failure modes, and corrosion resistance of the substrates were analyzed. The results indicated that the combined PAA/mechanical method improved the joint durability under hot-humid exposure. The treated surface, with a roughness of 2.85 μm, exhibited the best durability, losing only 6% of strength after exposure; the failure mode remained cohesive-failure dominant. The durability enhancement was attributed to the porous and moderate rough surface characteristics, which protected the substrate from corrosion and decreased the rate of moisture diffusion from the bonding interface, thereby reducing the degradation of the bonding interface and improving the durability of the joint.