A simple surface treatment and characterization of AA 6061 aluminum alloy surface for adhesive bonding applications

Structural adhesive bonding of aluminum is widely used in aircraft and automotive industries. It has been widely noted that surface preparation of aluminum surfaces prior to adhesive bonding plays a significant role in improving the strength of the adhesive bond. Surface cleanliness, surface roughness, surface wettability and surface chemistry are controlled primarily by proper surface treatment methods. In this study, we have employed a very simple technique influencing all these criteria by simply immersing aluminum substrates in a very dilute solution of sodium hydroxide (NaOH) and we have studied the effect of varying the treatment period on the adhesive bonding characteristics. A bi-component epoxy adhesive was used to join the treated surfaces and the bond strengths were evaluated via single lap shear (SLS) tests in pristine as well as degraded conditions. Surface morphology, chemistry, crystalline nature and wettability of the NaOH treated surfaces were characterized using various surface analytical tools such as scanning electron microscopy and energy dispersive X-ray analysis (SEM/EDX), optical profilometry, infrared reflection absorption spectroscopy, X-ray photoelectron spectroscopy, X-ray diffraction and contact angle goniometry. Excellent adhesion characteristics with complete cohesive failure of the adhesive were encountered on the NaOH treated surfaces that are comparable to the benchmark treatments such as anodization, which involve use of strong acids and multiple steps of treatment procedures. The NaOH treatment reported in this work is a very simple method with the use of a very dilute solution with simple ultrasonication being sufficient to produce durable joints.