Roll bonding of AA5052 and polypropylene sheets: Bonding mechanisms, microstructure and mechanical properties

Structural, microstructural and mechanical properties in roll bonding of AA5052 and polypropylene sheets have been evaluated in this study. The surface roughness of the AA5052 sheets, rolling temperature and the surface energy of polymer were selected as the bonding variables. The findings indicated that an increase in the surface energy of polypropylene by grafting maleic anhydride would result in higher bonding strength due to chemical interaction between the AA5052 and the maleic anhydride grafted polypropylene (PP-g-MAH). In fact, this reaction caused the formation of an interphase layer at the polymer side of the interface and the diffusion of aluminum into the PP-g-MAH layer. It was also observed that an increase in the rolling temperature increases bonding strength because the polymer penetrates the AA5052 surface irregularities more easily, the PP-g-MAH molecules move more smoothly toward the AA5052 surface, and finally there are more chemical interactions among the layers. An Increase in the bonding strength through increasing the AA5052 surface roughness was attributed to an increase of the van der Waals force and more interaction surface among the layers along with higher mechanical interlocking in the shear tension test.