Effect of surface pre-treatment on the adhesive strength of epoxy–aluminium joints

Abstract A detailed study of the effect of pre-treatment applied on the surface characteristics of aluminium substrates and on the adhesive strength of epoxy–aluminium joints is reported. The variation of the density, composition and aspect of the adherends were analysed as a function of the applied pre-treatment. In order to determine the influence of alloying elements, two different aluminium alloys were used, A1050 and A2024. The adhesive strength was measured by the lap shear test, using several epoxy resins to analyse the influence of the adhesive nature. A chromate-free treatment based on the sulphuric acid-ferric sulphate etch provided an improved joint strength compared to dichromate-sulphuric acid etching, alkaline etching or mechanical abrasion. This increase is associated to the porous oxide layer formed, but it depends on the adhesive nature used. The joints with Al–Cu–Mg alloy substrates generally presented higher adhesive strength values than those with pure aluminium adherends, due to the selective etching of some allowing elements and intermetallic compounds, which have different electrochemical potential.