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<p>Aluminum (Al) alloy-fluoropolymer hybrid structures are desired in the aerospace industry to meet requirements of weathering resistance, low-temperature performance, sealability, and light-weighting. However, achieving sound joining between these two materials remains challenging due to their substantial differences in physical and chemical properties and the inherently poor adhesive properties of fluoropolymers. In this study, friction lap joining (FLJ) was employed to join fluorocarbon polymer to Al alloy. Sulfuric acid anodization was introduced to modify the metal surface before joining for interfacial bonding enhancement. Systematic orthogonal experimental analysis corroborated that joining speed was critical for the lap-shear strength of joints, contributing 62.51% among joining parameters. Lowering joining speed would increase the heat input, promoting elemental diffusion and enhancing chemical bonding at the interface. However, excessively low joining speed would induce thermal degradation of the fluorocarbon polymer. Mechanical interlocking and chemical bonding synergistically enhanced the lap-shear strength to 22.6&#xa0;MPa. The chemical bonding between the Al alloy and the fluoropolymer was attributed to the formation of Al-F and Al-O-C bonds. These bonds were induced by the diffusion of fluorine and carbon atoms which could be enhanced by increasing heat input during joining process.</p>

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Friction Lap Joining of Aluminum Alloy and Fluorocarbon Polymer: An Emphasis on Interfacial Enhancement and Bonding Mechanism

  • 期刊论文

  • 发表日期：

    2026年2月16日

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  • Zhenkun Cheng,
  • Xin Zou,
  • Nannan Chen,
  • Feifei Xie,
  • Min Wang,
  • Yiwu Kuang,
  • Ke Chen

摘要

Aluminum (Al) alloy-fluoropolymer hybrid structures are desired in the aerospace industry to meet requirements of weathering resistance, low-temperature performance, sealability, and light-weighting. However, achieving sound joining between these two materials remains challenging due to their substantial differences in physical and chemical properties and the inherently poor adhesive properties of fluoropolymers. In this study, friction lap joining (FLJ) was employed to join fluorocarbon polymer to Al alloy. Sulfuric acid anodization was introduced to modify the metal surface before joining for interfacial bonding enhancement. Systematic orthogonal experimental analysis corroborated that joining speed was critical for the lap-shear strength of joints, contributing 62.51% among joining parameters. Lowering joining speed would increase the heat input, promoting elemental diffusion and enhancing chemical bonding at the interface. However, excessively low joining speed would induce thermal degradation of the fluorocarbon polymer. Mechanical interlocking and chemical bonding synergistically enhanced the lap-shear strength to 22.6 MPa. The chemical bonding between the Al alloy and the fluoropolymer was attributed to the formation of Al-F and Al-O-C bonds. These bonds were induced by the diffusion of fluorine and carbon atoms which could be enhanced by increasing heat input during joining process.