Influence of bio-inspired surface texture of additively manufactured 17-4 PH stainless steel adherends on the strength of adhesively bonded joints

The bonding potential of as-printed additively manufactured stainless steel is largely unknown, and the use of additional hierarchical bio-inspired surface texture has not yet been explored or characterized. In this study, it is demonstrated with the use of Selective Laser Melting (SLM) that a hierarchy of three surface features at different length scales can greatly improve the shear strength of metal-metal adhesive joints. The intrinsic stochastic texture of the SLM as-printed surface showed a high contact angle and a mixed failure with a dominance of adhesive failure . However, enhancing the as-printed surface with the Tree Frog (TF) and Fish Scale (FS) bio-inspired textures produced super-wetting surfaces, significantly improving the shear strength due to the synergistic effect of mechanical interlocking and physical adsorption adhesion mechanisms, resulting in mixed failure. The results indicated that the interfacial bonding performance was in line with the super-wetting behavior and was higher for the samples with a hierarchy of three surface features. The highest increase in bond strength was found for the tree frog hierarchical hexagonal texture (+70% compared to the as-printed texture). In contrast, abrasion of the as-printed surface with P1000-grit paper significantly reduced the surface roughness and increased the water contact angle, resulting in the lowest shear strength.