Super-high bonding strength of polyphenylene sulfide-aluminum alloy composite structure achieved by facile molding methods

A facile and environmentally friendly technology was proposed to form polyphenylene sulfide (PPS)-aluminum alloy (Al) composite structures with light weight and high interface bonding strength. The Al surface was modified by synergistic treatments of sandblasting and deionized water. The influences of surface roughness and the boehmite structure formed on the Al surface on the interface bonding strength of the molded PPS-Al composite structures were quantitatively discussed. When the relative content of AlOOH generated by the reaction of deionized water with Al was 0.236, the bonding strength increased to 32.3 MPa, which was 2.3 times higher than that of before the treatments. It was found that after annealing, the crystallinity of PPS and the bonding strength of PPS-Al were increased to 51.9% and 35.6 MPa, respectively. The high interface bonding strength can meet most of engineering requirements and has a valuable application potential in the aerospace and automotive fields. [Display omitted] •A facile technology to form PPS-Al composite structures with high bonding strength.•The relative content of AlOOH significantly affects the bonding strength of PPS-Al•After annealing, the bonding strength of the PPS-Al is increased by 10.2%–35.6 MPa.