Ultra‐high bonding strength of carbon fiber–doped polyamide–aluminum alloy composite structure achieved by changing crystallinity

Abstract Lightweight and high‐strength polymer–metal hybrid structures are favored for reducing material and energy consumption. In this study, carbon fiber‐reinforced polyamide 6 (CFPA) composite materials were prepared through melt blending, and 30 wt% CFPA exhibited the highest shear strength and lowest shrinkage rate among other carbon fiber contents. With pretreatments of anodizing and etching treatment, injection molded direct joining was employed to create polyamide 6 (PA)/CFPA–Aluminum alloy (Al) composites. The impacts of the injection temperature and speed on the bonding strength of the PA/CFPA–Al composite materials were investigated. The characterization results confirmed that carbon fiber doping reduces the coefficient of linear thermal expansion (CLTE) and enhances crystallization ability of PA. The higher injection temperatures and lower injection speed significantly increase the crystallinity of PA and the infiltration of the molten polymer into the nanoporous anodic aluminum oxide films. When the injection temperature was 270°C and the speed was 6 mm/s, the bonding strength of the PA–Al hybrid structure reached a maximum of 36.6 MPa. When the injection temperature was 300°C, the bonding strength of the CFPA–Al hybrid structure reached a maximum of 40.8 MPa. Adhesive parts with high shear bonding strength are critical to satisfying engineering requirements and have significant potential, particularly in polymer–metal composite structures. The polymer‐metal hybrid structure can meet the high interfacial bonding strength required in most engineering applications. Highlights Injection temperature and speed in IMDJ affect PA crystallinity. Carbon fiber doping reduces the CLTE of PA and increases the shear strength. High temperatures and low injection speeds are beneficial to adhesives. The bonding strength of PA–Al reached a maximum of 36.6 MPa. The bonding strength of CFPA–Al reached a maximum of 40.8 MPa.